319.21.CR.O Diesel Plant Fitting

ZIMBABWE
MINISTRY OF HIGHER AND TERTIARY EDUCATION, INNOVATION,

SCIENCE AND TECHNOLOGY DEVELOPMENT
HIGHER EDUCATION EXAMINATIONS COUNCIL

(HEXCO)
2021
REGULATIONS AND SYLLABUS
FOR
NATIONAL CERTIFICATE
IN
DIESEL PLANT FITTING
Course Code: 319/21/CR/0
Implementation Date: June 2021
1
PREAMBLE
The course is designed to develop a Diesel Plant Fitting Artisan with knowledge, skills and
attitudes required to competently practice in the Automotive Industry. The entry requirement are
5 ‘O’ Level subjects passed with grade C or better including English, Mathematics and a relevant
Science subject plus any other three subjects or National Foundation Certificate (NFC) subjects
or equivalent. The duration of the course is two years with one year (1 656 hours) of theory and
another year of On-the-Job Education and Training (OJET). The course is offered on a full time,
part time, Block release or Open Distance e-Learning (ODEL) basis. Assessments are done
through final written examinations and continuous assessment.
CONSULTATION YEAR
1. Motor Trade Association of Zimbabwe (MTAZ) 2020
2. Motor Industry Employer’s Association of Zimbabwe 2020
3. BARZEM 2020
4. Gulliver 2020
5. National Railways of Zimbabwe (NRZ) 2020
6. Wankie Colliery Company 2020
2
PART I: COURSE REGULATIONS
1.0 TITLE AND LEVEL OF AWARD
National Certificate in Diesel Plant Fitting
2. 0 AIM OF THE COURSE
The aim of the course is to develop a Diesel Plant Fitting Artisan with the knowledge,
skills and attitudes to be able to service, repair and modify heavy-duty vehicle, plant and
equipment operating systems.
3.0 COURSE LEARNING OUTCOMES
At the end of the course the student should be able to:
3.1 apply knowledge of Diesel Plant Fitting workshop tools, equipment and operating
principles in trouble shooting
3.2 service, recondition and modify heavy vehicle plant and equipment
3.3 maintain heavy vehicles, machinery and related components
3.4 apply mathematical concepts in solving problems for Diesel Plant Fitting
3.5 apply scientific principles to solve problems for Diesel Plant Fitting
3.6 demonstrate knowledge of technical drawing
3.7 apply communication skills to enhance performance in Diesel Plant Fitting
3.8 demonstrate knowledge of information communication technology
3.9 demonstrate patriotism on national issues
3.10 engage in entrepreneurial activities
3.11 apply acquired knowledge and skills in real world of work
3
4. 0 COURSE STRUCTURE
SUBJECT TITLE SUBJECT NOTIONAL

CODE HOURS
1 Diesel Plant Fitting Technology 319/21/S01 544
2 Diesel Plant Workshop Practice and Processes (Skills 319/21/S03 216
Proficiency Assessment)
3 Fitting & Machining (Practical Workshop Assessment) 319/21/S02 144
4 Engineering Mathematics 346/18/S02 140
5 Engineering Science 346/18/S03 140
6 Engineering Drawing 346/18/S04 180
7 Basic Communication 310/19/S02 80
8 Fundamentals of Information Technology 310/19/S07 80
9 National Studies 401/19/S01 80
10 Entrepreneurial Skills Development 402/19/S01 80
11 On The Job Education Training 319/21/S14 1 year
TOTAL 1 684 Hours
5.0 DURATION
The duration of the course is two years with one year (1 684 hours) of theory and another
year of On-the-Job Education and Training (OJET).
6.0 ENTRY REQUIREMENTS
The entry requirement are 5 ‘O’ Level subjects passed with grade C or better including
English, Mathematics and a relevant Science subject plus any other three subjects or
National Foundation Certificate (NFC) subjects or equivalent.
7.0 MODE OF STUDY
Full Time : 1 684 hours plus one year OJET

Part Time : 1 684 hours plus one year OJET
Block Release: 1 684 hours plus one year OJET
ODeL : 1 684 hours plus one year OJET
4
8.0 ASSESSMENT
8.1 ASSESSMENT SCHEME
MODE OF ASSESSMENT WEIGHTING

SUBJECT TITLE AND WRITTEN CONTINUOUS
CODE EXAMINATION ASSESSMENT
40% 60%
1 Diesel Plant Fitting 3 hour paper A Minimum of:
Technology 2 Assignments 20%
319/21/S01 (weighted 10% each)
2 Tests 20% (weighted 100%
10% each)
2 Practicals 20% (weighted
10% each)
2 Diesel Plant Fitting Submit Marks
Workshop Practice 100%
and Processes (Skill
Proficiency
Assessment)
319/21/S03
3 Fitting and Submit Marks 100%
Machining (Practical
Workshop
Assessment)
319/21/S02
3 Engineering A Minimum of:
Mathematics 3 hour paper 2 Assignments 20% 100%
2 Tests 20% (weighted
10% each)
10% each)
4 Engineering Science 3 hour paper A Minimum of:
346/18/S09 2 Assignments 20%
(weighted 10% each)
10% each) 100%
10% each)
5 Engineering 3 hour paper A Minimum of:
Drawing 2 Assignments 20%
5
10% each)
10% each)
6 Basic 3 hour paper A Minimum of: 100%
Communication 2 Assignments 20%
10% each)
10% each)
7 Fundamentals of 3 hour paper A Minimum of:
Information 2 Assignments 20%
Technology (weighted 10% each)
310/19/S07 2 Tests 20% (weighted 100%
10% each)
10% each)
8 National Studies 3 hour paper A Minimum of:
401/19/S01 2 Assignments 20%
(weighted 10% each)
10% each)
10% each)
9 Entrepreneurship 3 hour paper A Minimum of:
Skills Development 2 Assignments 20%
10% each)
10% each)
10 On the Job Training As per log book
319/21/S14 100%
9.0 GRADING
0% t0 49% - Fail
50% to 59% - Pass
60% to 79% - Credit
80% to 100% - Distinction
6
10.0 CONDITIONS OF AWARD
10.1 A candidate should attend at least 85% of learning sessions to qualify for
examinations.
10.2 The final mark should be obtained through aggregation provided the candidate
scores at least 40 % in each of continuous assessment and examinations.
10.3 The pass mark shall be 50 %.
10.4 Candidates should pass all subjects
11.0 RE-WRITE
11.1 Re-write(s) should conform to current course structure.
11.2 Candidates should pass at least two thirds of the course to qualify for a
referral.
11.3 Any candidate who fails to pass at least two thirds of the course should repeat the
whole course, including the subjects they would have passed.
11.4 There is no time limit for which to re-write a failed examination.
11.5 There is no aggregation for re-writes.
11.6 All re-writes should pass on performance in the examination.
11.7 If a candidate fails continuous assessment he/she repeats the subject
12.0 EXEMPTIONS
12.1 Exemptions are only granted in subjects already attained from a completed
accredited qualification provided an exemption certificate specifying subjects of
exemption is produced.
12.2 Exemption Certificate should be applied for at enrolment and produced before
registration for examinations.
13.0 IRREGULAR PRACTICES
13.1 Cheating in examinations will result in disqualification from the whole course and
all other HEXCO courses. The candidate will be suspended for two years.
13.2 Plagiarisms in any of the assessments will result in automatic disqualification in

the course and any other HEXCO courses and the penalty as in 13.1 will apply.
7
14.0 RESOURCES
14.1 Lecturers’ Qualifications:
National Diploma in Diesel Plant Fitting or equivalent, a teaching qualification

and at least five years post qualifying experience.
14.2 Infrastructure and Equipment
14.2.1 Theory classroom to accommodate at least 12 students per given time

(fitted with writing surface-e.g. Whiteboard).
14.2.2 Engineering Drawing Room fitted with appropriate drawing office
furniture to accommodate at least 12 students per given time (fitted with
writing surface).
14.2.3 Diesel Laboratory (fully equipped).
14.2.4 Automotive workshop equipped as follows.

- Sufficient DPF tool kits.
- Protected inspection pit, vehicle ramp or hoist.
- Workbenches providing at least 10 work stations for students.
- 12 x fitted bench vices.
- Fire-fighting appliances and Emergency Exit.
- Fire Aid Equipment.
- Hand-wash basins.
- Lifting equipment Mechanical, Electrical or Pneumatic.
- Pedestal drill.
- Bench grinder (fitter).
- Compressed Air Supply and Appliances.
- Hydraulics Laboratory.
- Pneumatics Laboratory.
14.3 Computer Laboratory equipped with
14.3.1 12 x Personal Computers

14.3.2 Computer Software (adequately licensed software to include:
- Spreadsheet.
- Word Processing.
- Database.
- DOS.
- MS Windows 95 or later.
14.3.3 Writing surface for the instructor (e.g. securely mounted Whiteboard).
14.4.4 Computer desks and chairs for at least 12 students (1 student per computer
recommended)
8
14.4 SUGGESTED REFERENCE BOOKS
1. Asmus A. (1981) Diesel engines and fuel system Butterworths London
2. Bland S. (1980) Diesel Engines Longman London
3. Cookery A.J. (1982) Graded Exercise in Technical Drawing Longman London
4. Crouse (1981) Automotive Electrical Systems Newness Basingstoke
5. Crouse & (1981) Automotive Electronic and Electrical McGraw-Hill New York
Anglin Equipment
6. Culphin C. (1981) Automotive Technician’s Handbook McGraw-Hill New York
7. Flood C.R. (1985) Farm Machinery Granada London
8. Gocring C.E. (1981) Fabrications, Welding & Metal Joining Butterworths London
Processes
9. Greer A. Et al (1990) Engine and Tractor Power Breton Basingstoke
10. Hillier and (1997) Tables, Data and Formulae for Engineers Thornes London
Pittuck
11. Kett P.W. (1981) Fundamentals of Heavy Vehicle Hutchinson

Technology
12. Maleckv V.I. (1982) Motor Vehicle Calculations and Science Chapman & Hall New York
Book Two
13. Mudd S.C. (1982) Diesel Engine Operation and Maintenance McGraw-Hill London
14. Mummy F.J (1990) Mechanical Science for Motor Mechanics Arnold London
(Book 2)
15. Nummey E.J. (1982) Vehicle Technology 2 Butterworths London
16. Pituck and (1981) Vehicle Technology 2 Butterworths London

Hillier
17. Schultz E.J. Fundamentals of Motor Vehicle Hutchinson New York

Technology
18. Schultz E.J. (1983) Diesel Mechanics McGraw-Hill New York
19. Schultz E.J. (1982) Diesel Equipment I: Lubrication, McGraw-Hill New York
Hydraulics and Brakes
20. Shorbolt C.R. (1982) Diesel Equipment II: Electro-Controls, McGraw-Hill London
Frames, Steering and Suspension,
Transmission
21. Whipp J. (1982) Technical Workshop Processes & Cassell London
9
Materials I.
22. Zammit S.J (1982) Motor Vehicle Craft Studies Part II MacMillan London
23. Mudd S.C. (1980) Motor Vehicle Engineering Longman New York
24. Crouse & (1990) Technology for motor Mechanics Books 1 McGraw-Hill New York
Anglin – 4.
25. Tucker H.F (1992) Automotive Manual Transmissions & Delmar/Breton London
Power Trains
26 Little & (1984) Automatic Transmissions Breton London

Edmondson
27.. Stone R. (1985) Diesel Mechanics MacMillan London
28 Watson & (1985) Introduction to Internal Combustion MacMillan London

Janota Engines
29. Goodger E.M. (1985) Turbo-Charging the Internal Combustion MacMillan London
30. Smith P.H (1970) Combustion Calculations: theory, Worked Foulis & Co. London
Examples and Problems
31. Martin A.L. (1970) Scientific Design of Exhaust & Intake English University London
Systems
32 Billet. W. (1980) Science & Calculations for Motor Vehicle American Technical New York
Technicians: Part I Publications
33. Dolan S. (1985) Automotive Engines: Maintenance & Heinemann

Practical Work: Parts I & II
34. Pippernger & (1983) Industrial Hydraulics McGraw-Hill New York

Hicks
35. Leeming, (1982) Heavy Vehicle Technology Hutchinson London

Hartley
36. Stroud K.A. (1995) Engineering Mathematics Bath Press London
10
PART II
SYLLABI CONTENT
COURSE STRUCTURE
SUBJECT TITLE SUBJECT DURATION

CODE (HOURS)
1 Diesel Plant Fitting Technology 319/21/S01 544
2 Diesel Plant Fitting Workshop Practice and Processes
(Skills Proficiency Assessment) 319/21/S03 216
3 Fitting and Machining (Practical Workshop Assessment) 319/21/S02 144
4 Engineering Mathematics 346/18/S08 144
5 Engineering Science 346/18/S09 144
6 Engineering Drawing 346/18/S04 144
7 Basic Communication 310/19/S02 80
8 Fundamentals of Information Technology 310/19/S07 80
9 National Studies 401/19/S01 80
10 Entrepreneurial Skills Development 402/19/S01 80
11 On the Job Education and Training 319/21/S14 1 year
TOTAL 1 684
11
SUBJECT: DIESEL PLANT FITTING TECHNOLOGY
CODE: 319/21/S01
DURATION: 544 HOURS
1.0 AIM OF THE SUBJECT
The aim of the subject is to provide the student with the knowledge, competencies and
attitudes required in the heavy duty plant and vehicle environment.
2.0 SUBJECT LEARNING OUTCOMES
By the end of the subject, the student should be able to:
3.1 practice health and safety procedures that are appropriate to the diesel plant
fitting workshop.
3.2 explain the operations of various types of diesel powered plant, equipment and
tractive units.
3.3 describe cooling systems in diesel powered plant, equipment and tractive units
3.4 demonstrate knowledge of lubrication procedures
3.5 explain intake and exhaust systems in diesel powered plant, equipment and
tractive units
3.6 apply transmission principles diesel powered plant, equipment and tractive units
3.7 demonstrate knowledge of braking systems in diesel powered equipment and
tractive units
3.8 outline operations of steering and suspension systems
3.9 diagnose and rectify electrical faults on diesel powered plant, equipment and
tractive units
3.10 demonstrate knowledge of special features of heavy plant/equipment
3.11 apply hydraulic principles in diesel powered plant, equipment and tractive units
3.0 TOPICS
Workshop environment
Engines
Cooling systems
Lubrication
Exhaust & intake systems
Transmission systems
Brakes
Steering & suspension systems
Introduction to vehicle body electro-technology systems
Special features of heavy plant/equipment
Hydraulics
12
4.0 CONTENT
4.1 WORKSHOP ENVIRONMENT

4.1.1 Explain workshop hazards that may occur in a Heavy Vehicle workshop.
4.1.2 Outline possible ways of reducing and eliminating hazards
4.1.3 Describe the procedure for handling workshop tools and equipment.
4.1.4 Demonstrate knowledge of firefighting equipment and their application to
different types of fires.
4.1.5 Explain the procedure for attending to fires in the workshop.
4.2 ENGINES
4.2.1 Explain with aid of sketches the layout, construction and operation of engine
components
4.2.2 Demonstrate knowledge of the following:
 history of C.I. Engines
 compression Ignition engine components and their functions
 types of engine block construction (mono-block)
 separate block and crankcase
 materials used in construction of engine blocks
 types of cylinder arrangements
 types of cylinder liners
4.2.3 Explain the procedure for honing liners
4.2.4 Identify the materials used in manufacturing crankshafts
4.2.5 Outline the procedures involved in crankshaft manufacturing
4.2.6 Demonstrate knowledge of types of firing order forms on engines from 4 cylinder
to 16-cylinder units
4.2.7 Explain how dynamic and static balance on a crankshaft are achieved
 types of con-rods
 means of piston to con-rod connection
 types of Big-end cap attachment to main journal
 construction of bearings and bushes
 bearing clearance
 importance of bearing torque
4.2.9 Identify materials used in the manufacture of pistons
4.2.10 Explain “piston slap”
4.2.11 Describe methods of overcoming piston slap
4.2.12 Explain the following:
 need for different diameters of the skirt, piston center and piston
crown
 piston clearances for given crown, centre skirt
 types of piston rings
 types of ring joints with aid of sketches
 use of ring gap and side clearance
4.2.13 Demonstrate knowledge of camshaft construction
4.2.14 Identify types of camshaft drives
13
4.2.15 Describe the types of valve operating mechanisms
4.2.16 Explain the following types of valves and materials:
 sodium cooled
 solid stem
4.2.17 Outline the need for:
 valve rotation
 valve clearances
 interference angle
4.2.18 Explain the ways of rotating valves.
4.2.19 Describe how heat is transferred from the valve head.
4.2.20 Outline the procedure of refacing valve seats and faces.
4.2.21 Explain types of valve guides and the materials used in the manufacture.
4.2.22 Identify types of valve springs
4.2.23 Discuss valve bounce
4.2.24 Describe the construction and operation of:
 Harmonic Balancers
 Countershafts
 Engine Mountings.
4.2.25 Demonstrate knowledge of the operating principles of C.I. Engines:

 Four stroke engine
 Two stroke engine.
4.2.25 Describe the following:
 Top Dead Centre (TDC)
 Bottom Dead Centre (BDC)
 stroke
 throw
 swept volume
 clearance volume
 compression ratio
 crank angularity
 ineffective crank angel
 requirements for efficient combustion
4.2.26 Describe three phases of combustion
4.2.27 Compare Indicator diagrams for constant Pressure Engines to constant volume
engines.
4.2.28 Explain with aid of diagrams the operation of:
 direct combustion chambers with and without a masked valve
 indirect combustion chambers

 valve timing
 Two-stroke vertical port type loop scavenging
 Cross-flow port type Two-stroke
14
 Uniflow Two-stroke
 Horizontally opposed piston
 Port and valve vertical engine
 Double acting Piston (two stroke).
4.2.30 Compare 4-stroke against 2-stroke cycle engines
 Power-to-weight ratio
 Volumetric efficiency and factors governing it
 Brake Power
 Indicated power
 Mechanical Efficiency
 Break Mean Effective Pressure (BMEP)
 Indicated Mean Effective Pressure (IMEP)
 Heat balance
 Thermal efficiency.
4.2.32 Compare C.I. to Spark Ignition (S.I.) engines in terms of:
 Construction
 Torque and power output.
 On-board diagnostics
 Sensors and actuators
 Electric diesel injection
 Motronic fuel injection systems
4.3 COOLING SYSTEMS

4.3.1 Explain the need for cooling engines
4.3.2 Demonstrate knowledge of the operation of AIR cooling system
4.3.3 Outline the maintenance procedure for an air cooling system.
4.3.4 Demonstrate knowledge of faults, causes and remedies concerning air cooling
systems problems
 water cooling components
 operation of WATER cooling systems
 the differences between types of water cooling systems
 maintenance procedures for a water cooling system
4.3.6 Describe heat transfer on an engine under the following:
 conduction
 convection
 radiation
4.3.7 Explain the operation of Marine Engine cooling system
15
4.4 LUBRICATING SYSTEMS
4.4.1 Explain the importance of lubricating moving parts
4.4.2 Describe types of friction on motor vehicles
4.4.3 Outline properties of the Diesel engine lubricating oil
4.4.4 Describe how oil is contaminated by:
 oxidation
 dilution
 sludge
4.4.5 Demonstrate knowledge of types of lubrication systems found on a vehicle
engine.
4.4.6 Explain components of the lubricating system
4.4.7 Demonstrate knowledge of the operating principles of types of lubricating system
filtration
4.4.8 Discuss relief valves under the following:
 ball type
 plunger type
 oil pumps
 oil coolers
 pressure gauges
4.4.9 Explain operation of cooler and filter by-pass valves
4.4.10 Outline the importance of crankcase ventilation (CV) and Positive Crankcase
Ventilation (PCV)
4.4.11 Compare CV to P C V types
4.4.12 Discuss oil pressure problems under the following:
 causes
 remedies
4.4.17 Explain causes of:
 oil consumption
 cavitation
 aeration
 leakage
4.5 SUPERCHARGES
4.5.1 Outline the importance of supercharging and turbocharging
4.5.2 Demonstrate knowledge of the operation of a roots type blower and turbocharger
4.5.3 Distinguish between the natural aspiration and super charging
4.5.4 Explain operation of:
 air cleaners/filters
 after and intercoolers
4.5.5 Discuss common faults on supercharges systems
16
4.6 TRASMISSION SYSTEM
4.6.1 With the aid of diagrams explain the operation of the following types of clutches:
 coil spring
 diaphragm
 dry and wet multi-plate type
 centrifugal type
 cone and dog type
 overrunning type (sprag of freewheel)
4.6.2 Demonstrate knowledge of different types of clutch plates
4.6.3 Outline the operation of clutch actuating mechanisms
4.6.4 Describe factors affecting torque transmitted by a clutch.
4.6.6 Demonstrate knowledge of clutch overhaul procedure and related adjustments
4.6.7 Discuss the clutch problems, causes and remedies
4.6.8 Explain the operation of hydraulic couplings
4.6.9 Differentiate between friction clutches and hydraulic couplings
4.6.10 Outline components of a fluid flywheel and their functions
4.6.11 With the aid of a diagram outline the operation of a fluid coupling
4.6.12 Differentiate between a fluid fly wheel and torque converter
4.6.13 Describe the operation of a single stage torque converter during:
 low speed (vortex flow)
 high speed (rotary flow)
 coupling point (lock up clutch)
4.6.14 Explain the importance of a torque divider
4.6.15 Demonstrate knowledge of the components of a torque divider
 power flow through the torque divider planetary gears and torque
converter
 function of retarders
 types of retarders
4.6.17 Discuss the maintenance procedures relating to hydraulic couplings
4.6.18 Identify functions of gearboxes
4.6.19 Outline the layout of the following gearboxes:
 sliding mesh
 collar (sleeve) shift
 constant mesh
 baulk ring
4.6.20 Explain operation of gearboxes and transfer cases
4.6.21 Demonstrate knowledge of the under-listed gears:
 Spur
 Helical
 double helical
 epicyclic
4.6.22 Compare epicyclic gearing to conventional gearing
4.6.23 Demonstrate knowledge of the operation of 3/4/5 speed sliding constant mesh
boxes
4.6.24 Outline the advantages and disadvantages of sliding/collar shift boxes
17
4.6.25 Examine the operations of Fuller Twin Countershaft gearboxes of various speed
ranges
4.6.26 Explain the operation of auxiliary/splitter boxes and transfer cases
4.6.27 Compare the Fuller twin counter shaft gearboxes to a conventional (sliding mesh
or collar single) gearbox
4.6.28 Describe the operation of the following:
 selector mechanisms
 locking and interlocking mechanisms
 speedometer drive mechanisms
4.6.29 Explain the functions of the following:
 oil gearboxes
 grades of oil used in manual gearbox
 methods of retaining oil in the gearbox
 method of oil distribution
4.6.30 Identify gearbox faults, causes and remedies
4.6.31.1 Demonstrate of the operation of the following:
 propeller shafts
 universal joints
 rear axles
 final drives
4.6.31.2 State the functions of sliding joints and power take-offs
4.6.31.3 Assemble propeller shaft and universal joints
4.6.31.4 Describe with aid of sketches the operation of the following:
 hooke type universal joints (with needle rollers)
 tractor joint
 ball and trunnion
 layrub coupling
 slip joint
 power take-offs and shields
4.6.31.5 Explain the importance of correct alignment of joints on propeller shafts
4.6.31.6 Describe function of a centre bearing
4.6.31.7 Explain the method of checking propeller shaft runout
4.6.31.8 Discuss the principles of operations of:
 Hotchkiss drive
 Torque tube
4.6.31.9 Demonstrate knowledge of the following:
 torque reaction
 driving thrust
 brake reaction
 brake thrust
4.6.31.10 Explain the function of a final drive
4.6.31.11 Demonstrate knowledge of types of final drive units and their functions
4.6.31.12 Calculate the reduction ratios
4.6.31.13 Identify forces acting on a final drive unit
18
4.6.31.14 Demonstrate knowledge of the following:
 grades of oil
 methods of retaining the oil in final drive units
 function of a differential unit
 operation of the differential unit
 function of the rear axle casing
 “LIVE” and “DEAD” axles
 forces acting on axle casing
 rear hub arrangements
 forces upon the half shafts in the hub arrangements
 function of double reduction final drives
 reduction process for all types of Reduction Units
4.6.31.15 Explain the following:
 operation of third diff or inter-axle diff, with the aid of a diagram
 operation of positive pressure feed lubrication on inter-axle
differential
 operations of non-slip differential and limited-slip differential
 importance of non-slip and limited slip differentials
 uses of Extreme Pressure (EP) type oils
 uses of Tandem axles
 types of Tandem axles used on heavy vehicles
 procedure for Tandem axle alignment
 operating principles of two-speed axles
 operation of positive feed lubrication for inter-axle differential
4.6.32.1 Demonstrate knowledge of:
 history of Automatic Shift Transmissions
 functions of Automatic Shift Transmissions
 operation of Automatic Shift Transmissions
 components of an automatic transmission unit
 hydraulic oil flow system
4.6.32.2 Explain:
 Actuation – up shift and down shift
 oil flow and power flow
 operation of Lock up clutch
 diagnostic procedures to determine transmission
 procedure for rectifying identified Automatic Transmission System
faults
 stall-test procedure and pressure checks
19
4.7 BRAKES
4.7.1 Demonstrate knowledge of:
 braking efficiency
 functions of the braking systems
 single line hydraulic braking system
 dual line hydraulic braking system
 methods of actuating brake shoes and disk pads
 operating principle of the hydraulic brake actuating system
 operation of the following master cylinders:
 Lockheed (single line)
 Girling (single line)
 Tadem
4.7.2 Compare single line and dual line braking systems
4.7.3 Describe the operating principles of the following brake wheel assemblies:
 single piston
 double piston
4.7.4 Explain operating principles of the following brake shoe assemblies:
 Leading Trailing Shoe
 Twin Leading Shoes
 Duo-servo
4.7.5 Discuss the operation of both a single piston disc brake calliper and a two piston brake
calliper
4.7.6 Compare disk brakes to drum brakes
4.7.7.1 State the function of a brake pressure regulating valve
4.7.7.2 Describe the operation of a hydraulic brake pressure regulating valve
4.7.7.3 Identify the type of fluid used in a hydraulic braking system
4.7.7.4 Explain the operation of the linkages of a hand-brake mechanism, together with its means
of compensation
4.7.7.5 Demonstrate knowledge of the following brake faults:
 unequal braking on any axle
 spongy brake pedal
 no pedal pressure
 excessive pedal travel
 binding brakes
 brake fade
 brake pedal oscillation (vibration)
4.7.7.6 Identify materials used as brake friction
4.7.8.1 State the components of a basic air braking system
4.7.8.2 Outline the principle operation of an air braking system
4.7.8.3 Compare the various types of air braking systems
4.7.8.4 Outline the service procedure for air braking systems
4.7.9.1 Outline the history of engine brakes
4.7.9.2 Identify the functions of an engine braking system
4.7.9.3 Name types of engine brakes
4.7.9.4 Explain the operation of the exhaust braking systems
20
4.8 STEERING SUSPENSION
4.8.1 Define key concepts
4.8.2 Identify the following types of:
 suspension
 axles
4.8.3 Explain the operation of spring type suspension
4.8.4 Differentiate between constant-rate springs and variable-rate springs
4.8.5 Describe the operation of:
 Auxiliary springs
 Tandem axle suspension with an Equalizer beam
 air springs fitted on air ride suspensions
 lever type dampers
 telescopic type dampers
4.8.6 Identify types of boggie arrangement
4.8.7 Illustrate operation of the hydrostatic suspension
4.8.8 Trouble-shoot suspension system problems
4.8.9 Explain the function of Heavy Plant steering systems.
4.810 Demonstrate knowledge of types of steering systems
4.8.11 Explain:
 steering geometry
 Toe-in and Toe-out
 effect of misalignment on wheel wear
 wheel alignment and adjustment procedure
 operation of steering boxes
 use of hydraulic-assistance in steering systems
 operation of a basic hydraulically assisted steering system
 function of a knuckle pin (kingpin) and stub axle
4.8.12 Distinguish the following types of front axle:
 Dead (non-driving)
 Live (driving).
4.8.13 Distinguish the following types of Kingpins:
 Straight with grease nipple
 Tapered or sealed.
4.8.14 Describe the function of the steering stop adjustment
4.8.15.1 Demonstrate knowledge of types of:
 wheels
 rims
 tyres
4.8.15.2 Explain:
 wheels’ means of attachment to the hub
 wheel bearing adjustment procedure
 wheel and tyre runout check
 ways of wheel hub lubrication and sealing
 types of wheel-studs
 types of rims
 tubes and tubeless tyres
21
4.8.15.3 Match tandem drive axle tyres
4.8.15.4 Describe types of tyre treads found on heavy duty vehicles
4.8.15.5 Select tyres to satisfy loading, speed and legal requirements
4.8.15.6 Explain effects of over- or under-inflation of tyres
4.8.15.7 Identify types of ply tyres
4.8.15.8 Demonstrate knowledge of ply rating for tyres
4.8.15.9 Outline checks to be made before wheel alignment gauges are used on vehicle’s
steering system
4.15.10 Describe:
 effects of unbalanced wheel and tyre on vehicles
 methods of repairing wheels and tyres
4.9 INTRODUCTION TO VEHICLE BODY ELECTRO-TECHNOLOGY SYSTEMS

4.9.2 Explain the principle of operation of the following chassis electrical systems:
 anti-lock brakes
 traction and stability control
 automatic transmission
 electric power steering
 electronic limited slip differential
 brake assist systems
4.10 SPECIAL FEATURES OF HEAVY PLANT & EQUIPMENT

 operation of an undercarriage of a track-type
 Track frame
 Types of track adjusters
 Drive sprockets
 Rollers and idlers
 Track and chain
4.10.3 Describe location of wear measurement points on the Tractor’s undercarriage
4.10.4 Explain operation of the Caterpillar elevated system
4.10.5 Compare the Caterpillar elevated system to the ordinary type
4.10.6 Explain operation of steering clutches used on Track-type tractors
4.10.7 Explain operation of expander tubes type brakes
4.10.8 Describe methods of checking frame alignment
4.10.9 Demonstrate knowledge of operation of:
 Track-type tractor final drive and types of sprockets
 Wheeled Loader frames and suspension
 Grader final drive, brakes and steering
 Scrapper power trains as used on sing engine and twin engine scrappers
 Epicyclic final drives on various units of Heavy Duty Earth-moving
Plant
22
 hydraulic system used on:
 Rear Dumpers
 Front-end loaders
 Scrappers
 Graders
 Bulldozers
4.10.10 Describe the construction of off-highway tyres fitted on Heavy Duty trucks,
detailing the following:
 Tread
 Tyre wall
 Chafer strip
 Casing plies
 Apex strip
 Bead Wire
 Bead Wrap
 Inner Linear
 Tyre code
4.10.11 Explain:
 why traction chains are fitted on off-highway tyres
 why tyres are filled with water (i.e. on Heavy Duty and Tractors)
 reasons for correct off-highway tyre inflation
 type of inflation required for:
 Sandy conditions
 Muddy conditions
 Rocky conditions.
 methods of tyre changing
4.11 HYDRAULICS
4.11.2 Demonstrate knowledge of:
 hydraulics principles
 hydraulics system layout
 hydraulics tanks, filters, coolers, seals and connections
 Pumps
 Valves
 Actuators
 Accumulators
23
5.0 ASSESSMENT SCHEMES
WRITTEN COURSEWORK
EXAMINABLE
EXAMINATION ASSESSMENT TOTAL
SUBJECT
40% 60%
Diesel Plant Fitting 3-hour paper A minimum of 100%
Technology  2 assignments 20%
 2 Practicals 20%
(weighted 10% each)

 2 Tests 20%
(weighted 10% each)
6.0 ASSESSMENT SPECIFICATION GRID
TOPIC TOPIC WEIGHTING%

NO.
1 Workshop Environment 5
2 Engines 12
3 Cooling Systems 15
4 Lubrication 5
5 Exhaust & Intake Systems 15
6 Transmission Systems 10
7 Brakes 5
8 Steering & Suspension Systems 15
9 Introduction To Vehicle Body Electro-Technology Systems 5
10 Special Features Of Heavy Plant/Equipment 15
11 Hydraulics 3
Total 100%
24
7.0 SUGGESTED REFERENCES
AUTHOR YEAR TITLE PLACE PUBLISHER

ASMUS A. 1981 Diesel Engines London Longman
BLAND S. 1980 Graded Exercises I Technical Drawing London Longman
CULPHIN C. 1981 Farm Machinery New York Granada
FLOOD C.R. 1985 Fabrication, Welding and Metal Joining Processes London Butterwort
h
GOERING 1981 Engine and Tractor Power London Breton
C.E.
GREER A. et 1990 Tables, Data and Formulae for Engineers Basingstok Thornes
al e
HILLIER 1977 Fundamentals of Heavy Vehicle Technology London Hutchinson
&PITTUCK
MALEEVV.J. 1982 Diesel Engines Operations and Maintenance New York McGraw-
Hill
NUNNEYE.J. 1982 Engine Technology 1 London Butterwort
h
SCHULTZ 1981 Diesel Mechanics New York McGraw-
E.J. Hill
SCHULTZ 1983 Diesel Equipment i: Lubrication, Hydraulics and New York McGraw-
E.J. Brakes Hill
SCHULTZ 1982 Diesel Equipment II: Electro-Controls, Frames, New York McGraw-
E.J. Steering, Suspension and Transmission Hill
KOMATSU 2005 Product Bulletin, 4th Periodic Modification on Japan Komatsi
D60/65 Series Ltd
ST JOHN 2002 First Aid Manual London Penguin
AMBULANCE
BENJAMIN P. 2010 Occupational Health and Safety Handbook Harare Juta
& BARRY B.
BLACK B.J. 1996 Workshop Processes and Practices London Hodder
JOHN-DEERE 1972 Fundamentals of Service: Hydraulics Moline, Il Deere &
Co
25
SUBJECT: WORKSHOP PRACTICE AND PROCESSES (SKILLS
PROFICIENCY ASSESSMENT)
CODE: 319/21/S03
DURATION: 216 HOURS
The aim of the subject is to equip the student with knowledge and skills required in the
servicing, diagnosis and maintenance of heavy motor vehicles and plant equipment.
By end of the subject content, the student should be able to:
3.1 practice safety procedures in the workshop.
3.2 measure engine components for wear
3.3 use vehicle fault diagnostic equipment
3.4 rectify heavy motor vehicle and plant machinery faults
3.5 service heavy motor vehicles and plant machinery
3.6 demonstrate knowledge of heavy motor vehicles engine systems.
3.0 TOPICS
Diesel engines
Diesel engines cooling systems
Engine lubrication systems
Intake & exhaust systems
Heavy plant transmission systems
Hydraulics
26
4.0 CONTENT
4.1 DIESEL ENGINES

4.1.1 Distinguish between two-stroke and four-stroke CI engines.
4.1.2 Remove major components from engine.
4.1.3 Dis-assemble major components.
4.1.4 Clean all components.
4.1.5 Check component for wear
4.1.6 Re-assemble the major components
4.1.7 Assemble the subassembly
4.1.8 Fit in an injection pump to an engine
4.1.9 Demonstrate knowledge of Cummins pump-timing procedures
4.1.10 Carry out of timing a Detroit Diesel engine
4.1.11 Demonstrate knowledge of the timing of a Cummins engine from the cam-shaft.
4.1.12 Carry out engine dyno-testing
4.2 DIESEL ENGINE COOLING SYSTEMS

4.2.1 Identify components of the engine cooling system (both air- and water-cooled).
4.2.2 Conduct visual inspection of all components
4.2.3 Carry out pressure-test a water-cooled system for leaks
4.2.4 Inspect the following: thermostat, radiator, radiator cap, fan and temperature
gauge
4.2.5 Inspect water pump
4.2.6 Demonstrate knowledge of cooling system flush and bleed
4.2.7 Maintain air-cooled systems
4.2.8 Carry out test on thermostatically-operated shutters on both air- and water-cooled
systems.
4.2.9 Rectify cooling system faults
4.3 ENGINE LUBRICATION SYSTEMS

4.3.1 Identify engine lubrication system components
4.3.2 Inspect lubrication system for external leaks.
4.3.3 Check lubrication system pressures.
4.3.4 Maintain an oil pump
4.3.5 Demonstrate knowledge of lubrication system oil and filter
4.3.6 Check engine oil for any evidence of oil dilution or contamination
4.4 INTAKE AND EXHAUST SYSTEMS

4.4.1 Identify parts of the intake and exhaust systems
4.4.2 Replace air cleaner elements
4.4.3 Check intake and exhaust systems for restrictions
4.4.4 Refit Turbo-Chargers and Rootes Blowers
4.3.5 Perform engine shut on turbo-charges engine
4.3.6 Check turbo-boost pressure
27
4.3.7 Service intake and exhaust systems
4.3.8 Rectify faults relating to intake and exhaust systems
4.5 HEAVY PLANT TRANSMISSION SYSTEMS

4.5.1 Clutch Systems
a) Identify all components of the actuating system and the clutch assembly
b) Identify faulty or worn parts of a clutch
c) Adjust oil-spring clutch release fingers
d) Refit clutch system
e) Adjust foot pedal clearance
e) Test clutch system for malfunction on heavy plant and rectify fault
4.5.2 Drive Transmission gearboxes

a) Remove gearbox from heavy plant
b) Identify all worn components.
c) Check all worn components for wear
d) Re-assemble the gearbox
e) Repair auxiliary boxes, transfer boxes, transfer boxes and overdrive units
4.5.3 Prop, Shafts, UJ’s Rear Axle and Final Drives

a) Outline the functions of propeller shafts, U.J’s, Sliding joints and power
take-offs
b) Assemble the propshaft and U.J.
c) Demonstrate knowledge of the following:
 Hooke Type U.J. (with needle rollers)
 Tractor Joint
 Ball and Trunnion
 Layrub Coupling
 Slip joint
 Power Take-Offs and shields
d) Align joints on propeller shafts (propshafts)
e) Demonstrate knowledge of the layout of a centre bearing
f) Apply the method for checking propshaft runout
g) Demonstrate knowledge of the principles of operations of the:
 Hotchkiss drive
 Torque tube
h) Explain:
 the function of a final drive
 types of final drive units
 forces acting on a final drive unit
 grades of oil
 methods of retaining the oil in final drive units
i) Calculate the Reduction Ratios
j) Demonstrate knowledge of the:
 function of the rear axle casing
 “LIVE” and “DEAD” axles
28
 forces acting on axle casing
 rear hub arrangements
 forces upon the half shafts in the hub arrangements
 problems relating to prop shafts, U.J’s and rear axles, their
causes and remedies
 function of double reduction final drives
 types of double reduction final drive and reduction hubs
 reduction process for all types of Reduction Units
 operation of third diff or inter-axle diff
 operation of positive pressure feed lubrication on inter-axle
differential
 operations of non-slip differential and limited-slip
differential
 uses of Extreme Pressure (EP) type oils
 types of Tandem axles commonly used on Heavy Vehicles
 2 Speed Axle and state the need for two-speed axles
 operating principle of two-speed axles
 actuating Two Speed axles
 operation of positive feed lubrication for Inter-axle
differential
 Tandem axle alignment.
UNDER CARRIAGE
Demonstrate knowledge of the following:
 Sprockets
 Roller
 Tracks
 Track adjuster
 Idler
4.6 BRAKES
4.6.1 Hydraulic and Mechanical Systems
a) Identify the functions of the braking systems.
b) Demonstrate knowledge of:
 a Single Line hydraulic braking system
 a Dual Line hydraulic braking system
c) Apply methods of actuating brake shoes and disk pads
d) Demonstrate knowledge of the:
 operating principle of the hydraulic brake actuating
system
 operation of the following master cylinders
 operating principles of the following brake wheel
assemblies
 operating principles of the following brake shoe
assemblies
29
 a single piston disc brake calliper
 a two piston brake calliper
 function of a brake pressure regulating valve
 operation of a hydraulic brake pressure regulating valve
 type of fluid used in a hydraulic braking system
 operation of the linkages
 braking efficiency
 a hand-brake mechanism, together with its means of
compensation
 materials used as brake friction material
4.6.2 Braking Systems

Demonstrate knowledge of:
 components of a basic air braking system
 operation principle of an air braking system
 operation and layout of:
 spring brake system
 dual system
 three line system
 service procedure for air braking systems
4.6.3 Engine Brakes

Demonstrate knowledge of the:
 component of the Exhaust Braking Systems
 operation of exhaust braking system
4.7 Heavy Duty Plant Steering Systems & Front Axle(s)

Demonstrate knowledge of:
 function of Heavy Plant steering systems
 types of steering systems
 different types of steering system
 steering geometry
 Ackerman Angle (Principle)
 Toe-in and Toe-out
 wheel alignment procedure
 effect of misalignment on wheel wear
 types of steering boxes
 hydraulic-assistance in steering systems
 operation of a basic hydraulically assisted steering system
 trouble-shooting hydraulically assisted steering problems
 types of front axle
 operation of a live front axle
 beam type non-driving axle
 function of a knuckle pin (kingpin) and stub axle
 types of Kingpins
 steering stop adjustment
30
4.8 HYDRAULICS
 hydraulics system layout
 hydraulics principles
DIESEL LABORATORY
A) FUNDAMENTALS OF DIESEL FUEL

 history of diesel engine
 production of diesel fuel
 properties of diesel fuels
 use of diesel fuel
 combustion process
 why diesel fuels are used in compression engines
Compare diesel fuel to petrol
B) DIESEL FUEL SUPPLY SYSTEMS

 operation of major components of fuel supply system
 types of fuel supply layouts
 operation principles of:
 tanks and line connections
 fuel and lines and connections
 supply filters ( primary and secondary)
 checks carried out on supply systems
C) FUEL INJECTORS
 Outline the function of fuel injectors
 Repair/replace faulty parts
 Assemble the pump
 Calibrate and phase the pump on a test stand
 Identify types of governors fitted on Diesel fuel injection pumps (in line)
 Adjust:
 Pneumatic
 Mechanical
 hydraulic governors
 Adjust idle and maximum speeds on pump
 Fit injection pump on the engine
 Check proper function of pump
 Identify types of injector nozzles
 Demonstrate knowledge of the:
 operation of a closed type of injectors
31
 cracking pressure of injectors suitable for direct and indirect
injection
 injectors used in direct and indirect injection
 procedure of reconditioning injectors
 checks carried out on an injector after overhaul
 Carry out the following tests:
 cracking pressure test
 seat dryness test
 spray pattern test
 leak-back test
D) DIESEL FUEL INJECTION PUMPS (PORT & HELIX)

 functions of fuel injector pumps
 components parts of the pump
 parts of the fuel injector pump
 fuel metering principles
 operation of a delivery valve
 phasing and calibration
 how the control or quantity and time of injection is adjusted
E) GOVERNORS
 importance of a governor
 types of governors
 low and high idle speed
 speed drop
 maximum speed full load
 maximum torque speed
 minimum torque
 over-speed
 hunting , sensitivity, stability and promptness
 governor cut-off speed
 operation of governors listed above
F) OTHER TYPES OF FUEL SYSTEMS

 Identify functions of a unit injection
 Sketch the layout of the Detroit Diesel injection system
 Compare the D.D systems to other types
 Describe the tune up procedure
 Explain operation of caterpillar sleeve metering
 Sketch the pumping elements of caterpillar sleeve metering
 Apply metering principles
 Describe the control of quantity by adjustment of sleeve
 Examine operation of the distributor Type Pump
 Outline the fuel system layout of CAU (DPA Pump)
32
 Explain how injection advance and retard occurs
 Explain how fuel is governed by-:

 hydraulic governor
 mechanical governor
 Distinguish the difference in construction and operation of D.P.A and the Rate
Master rotary pumps
 Explain the developments of pressure- time metering, principles in Cummins fuel
system
 Identify problems relating to rotary pumps,
 Explain the developments of pressure- time metering, principles in Cummins fuel
system
 Outline of a Cummins fuel system
 Identify components of a PT system
 Identify types of fuel pumps
 Describe operation of the shutdown valve, gear pump and pulsating damper
throttle shaft and sleeve plunger and barrel governor and button
 Explain PTG fuel calibration procedure
 Describe the fuel flow and metering an injector
 Sketch a cam profile
 Relate camshaft rotation to injection during metering injection and safer injection
 Describe injector service procedures, tests and injector timing
G) ANTI-POLLUTION CONTROL DEVICES

 purpose of anti- pollution devices
 types of anti- pollution devices
 operation of anti-pollution devices
EXAMINABLE COURSEWORK ASSESSMENT

TOTAL
SUBJECT
Diesel Plant Workshop Submit Marks (Continuous Assessment guided by
Practice & Processes (Skills the Skills Proficiency Schedule) 100%
Proficiency Assessment)
319/21/S03
33
TOPIC NO. TOPIC WEIGHTING%

1 DIESEL ENGINES 20
2 DIESEL ENGINES COOLING SYSTEMS 15
3 ENGINE LUBRICATION SYSTEMS 10
4 INTAKE & EXHAUST SYSTEMS 15
5 HEAVY PLANT TRANSMISSION SYSTEMS 20
6 HYDRAULICS 10
7 DIESEL LABORATORY 10
TOTAL 100%
AUTHOR YEAR TITLE PLACE PUBLISHER

ASMUS A. 1981 Diesel Engines London Longman
BLAND S. 1980 Graded Exercises I Technical Drawing London Longman
CULPHIN C. 1981 Farm Machinery New York Granada
FLOOD C.R. 1985 Fabrication, Welding and Metal Joining Processes London Butterwort
h
GOERING 1981 Engine and Tractor Power London Breton
C.E.
GREER A. et 1990 Tables, Data and Formulae for Engineers Basingstok Thornes
al e
HILLIER 1977 Fundamentals of Heavy Vehicle Technology London Hutchinson
&PITTUCK
MALEEVV.J. 1982 Diesel Engines Operations and Maintenance New York McGraw-
Hill
NUNNEYE.J. 1982 Engine Technology 1 London Butterwort
h
SCHULTZ 1981 Diesel Mechanics New York McGraw-
E.J. Hill
SCHULTZ 1983 Diesel Equipment i: Lubrication, Hydraulics and New York McGraw-
E.J. Brakes Hill
SCHULTZ 1982 Diesel Equipment II: Electro-Controls, Frames, New York McGraw-
E.J. Steering, Suspension and Transmission Hill
KOMATSU 2005 Product Bulletin, 4th Periodic Modification on Japan Komatsi
D60/65 Series Ltd
ST JOHN 2002 First Aid Manual London Penguin
AMBULANCE
BENJAMIN P. 2010 Occupational Health and Safety Handbook Harare Juta
34
& BARRY B.
BLACK B.J. 1996 Workshop Processes and Practices London Hodder
JOHN-DEERE 1972 Fundamentals of Service: Hydraulics Moline, Il Deere &
35
SUBJECT: FITTING AND MACHINING (PRACTICAL WORKSHOP
ASSESSMENT)
CODE: 319/21/SO2
DURATION:
The aim of the subject is to equip the student with knowledge and skills applicable in
diesel plant fitting workshop.
By the end of the subject the student should be able to:
2.1 explain bench fitting procedures

2.2 demonstrate knowledge of fitting techniques
2.3 carry out sheet metal work in a workshop
2.4 demonstrate knowledge of turning
2.5 apply cutting theory in fitting and machining
2.6 demonstrate knowledge of metallurgy in diesel plant fitting workshop
2.7 use screws and threads in joining metals in a workshop
2.8 demonstrate knowledge of limits and fits
2.9 apply welding in diesel plant fitting workshop
3.0 TOPICS
Bench fitting
Fitting
Sheet metal work
Turning
Cutting theory
Metallurgy
Screws and threads
Limits and Fits
Welding
36
4.0 CONTENT
4.1 BENCH FITTING
4.1.1 WORKSHOP SAFETY
 Identify health and safety precautions relevant to diesel plant fitting
workshop
 Maintain proper lighting and sanitation in the workshop
 Implement all relevant legislation on workshop health and safety
 Carry out the following fire procedures:
 fire drills
 fire precautions
 fire classification
 Describe the procedure to be followed in case of a fire breaking out in the
workshop
 Operate firefighting equipment
 Outline measures that can reduce the risk of fires in the workshop
 Demonstrate knowledge of emergency electrical isolation switches in the
workshop
 Carry out remedial action in case of emergencies that involve:
 electricity
 oils
 toxic
 inflammable gases and chemicals
 Demonstrate knowledge of the correct procedure for lifting and moving
heavy materials or equipment in a workshop
 Implement safety precautions relating to machines and machine tools
4.1.2 USE OF HAND TOOLS
 Identify hand tools used in automotive engineering machine shop

 Demonstrate knowledge of care and maintenance of hand tools
 Perform metal removal operations to given specifications using
Scrappers
 Carry out hand broaching operations to specifications
4.1.3 MACHINE TOOLS
 Operate pillar and pedestal drills to perform specific machining or

metal removal tasks
 Use reamers to produce required dimensions and finish
 Demonstrate knowledge of using taps and dies
4.1.4 MARKING-OUT TOOLS
37
 Define key concepts
 Outline the importance of marking out tools in an automotive
engineering workshop
 Identify marking-out tools used in an automotive engineering
Workshop
 Demonstrate knowledge on the proper use, care, maintenance and
storage of the marking out tools
 Apply principle of marking out
 Outline the care, maintenance and storage of marking out tools
4.2 FITTING
4.2.1 MARKING-OUT PRACTICE
 Demonstrate knowledge of Copper Sulphate’s use in marking-out

 Perform Marking-out for specific tasks
 Measure given Automotive components
 Determine status of a product (tolerances).
4.2.2 DRILLS AND DRILLING
 Demonstrate knowledge of the following:

 Operating various types of drilling machines
 Servicing of drilling machines
4.2.3 GRINDERS
 Use bench grinder to sharpen tools
4.2.4 STOCKS AND DIES

 procedure for tapping using taps and dies
 repair damaged threads using stocks and dies
 cut new threads on shaft and bolts using stocks and dies
 Identify thread type and size
38
4.3 SHEETMETAL WORK
4.3.1 SHEET-METAL WORKING TOOLS AND WORK PRACTICE

 sheet metal working tools and equipment
 function of sheet metal working tools and equipment
 health and safety precautions to be followed when working with
sheet metals
 interpreting engineering drawings
 marking out to given specifications
 cutting from drawings
 apply sheet metal work techniques on repair/modification of
required objects
4.4 TURNING
 Identify components of a lathe

 Explain the functions of the parts, switches and controls
 Demonstrate knowledge of the:
 lathe cutting tools and tool accessories
 operation of the centre lathe (using all switches and manual controls)
 requirement for planned maintenance of tuning machines
 work-holding and work-supporting devices and their accessories
 mounting and supporting work-piece
 tool holding and supporting devices
 mounting cutting tool
 setting to centre height
 producing plain and stepped shafts
4.4.3 KNURLING AND PARTING-OFF
 Apply turning techniques for Knurling and Parting-Off
4.4.4 DIFFERENT HOLDING METHODS
 Apply different holding methods such as turning between centres or using

the four-jaw chuck to perform specified tasks
39
4.5 CUTTING THEORY
4.5.1 CUTTING ACTION AND CUTTING ANGLES

 Demonstrate knowledge of the importance of cutting action and cutting
angles
 Explain factors that determine the selection of speeds and feeds for
specified operations
 Determine speed and feed rate for given operations
4.5.2 CUTTING TOOLS
 Identify cutting tools

 Explain uses of lathe tools
 Demonstrate knowledge of maintaining cutting tools
4.6 METALLURGY
4.6.1 FERROUS AND NON-FERROUS METALS
 Outline properties of ferrous and non-ferrous metals

 Use knowledge of Ferrous and non-ferrous metals in the selection of
suitable material for a given task.
4.6.2 METAL PROPERTIES AND HEAT TREATMENT
 Describe the properties of metals used in the manufacture and/or repair of

motor vehicle components
 Explain the heat treatment process for given metals
 Describe the factors governing the selection of material for a given task
4.6.3 SRENGTH OF MATERIALS
 Determine suitability of material for use in a given engineering task.

 State the limitations of given materials (i.e. Stress, Strain and Fatigue)
taking into consideration all other information.
40
4.6.4 ALLOYS AND ALLOYING ELEMENTS
 Describe an alloy
 Explain uses of alloys in automotive engineering
 Outline the importance of alloying elements in automotive engineering
 Identify materials used as bearings or in bearing construction
4.7 SCREW AND THREADS
4.7.1 FORMS AND GAUGES

 Use screw thread forms and gauges
4.7.2 SCREW/THREAD-CUTTING PRACTICE

 Demonstrate knowledge of cutting standard Vee threads
 Describe the effects of pitch errors
 Explain methods of reducing pitch errors
4.8 LIMITS AND FITS
4.8.1 TYPES OF FIT ON MACHINES

 types of fit used on motor vehicles
 limits of size
 tolerance
 allowance
 differences between the methods employed in a manufacturing
organisation
 modern limit system
4.9 WELDING
4.9.1 GAS - & ARC – WELDING SAFETY
 Identify components that that constitute an Oxy-Acetylene welding/cutting

kit.
 Observe safety requirements when operating Oxy-Acetylene
cutting/welding equipment
 Perform Oxy-Acetylene welding and cutting to repair or fabricate
Automotive components
 Describe the composition of gas welding rods used for joining metals
 Outline the dangers that exist from improper use, care or maintenance of
gas welding/cutting equipment
 Carry out safety checks on assembling gas welding equipment
 Demonstrate knowledge of the following flames:
41
 carburising flame
 neutral flame
 oxidising flame
 Apply the following welding techniques:
 left-ward or forward welding
 right-ward or backward welding
 modification of techniques (e.g. for welding Aluminium)
 Identify types of weld joint used in Vehicle Body Building and repairing
 Outline the care and maintenance of gas welding equipment
 Demonstrate knowledge on the use of other gas welding/cutting
appliances
 Identify gas welding faults
 Describe methods of reducing or avoiding the possibility of, and
correcting, such faults
 Outline the properties of fluxes
 Explain uses of welding and soldering fluxes
 Explain properties of:
 brazing rods
 aluminium brazing
 bronze welding
 Describe methods of removing fluxes
4.9.3 SOFT - SOLDERING

 soft-soldering methods
 tools and equipment used in the repair vehicle body sections or
components
 soft soldering process
 type of soldering joint used in the motor industry
 composition of soft solders for the joining
4.9.4 ELECTRIC – ARC WELDING TECHNIQUES
 Outline the principles of arc welding

 Identify components that together make up an electric arc welding plant
and equipment
 Distinguish Electric Arc Welding from Gas Welding
 Demonstrate knowledge of the arc welding procedure
 Explain methods of controlling distortion in arc welding
 Describe pipe-welding for carbon steel
 Describe pipe-welding for alloy steel
 Outline methods used in the mechanical testing of welded joints
 Explain the methods used in non-destructive testing of welded joints
42
EXAMINABLE COURSEWORK
TOTAL
SUBJECT ASSESSMENT
Fitting and Machining Submit Marks
319/21/SO2 100%
TOPIC NO. TOPIC WEIGHTING %

1 Bench Fitting 10
2 Fitting 10
3 Sheet metal work 10
4 Turning 10
5 Cutting theory 10
6 Metallurgy 15
7 Screws and threads 10
8 Limits and Fits 10
9 Welding 15
Total 100
43
SUBJECT: ENGINEERING MATHEMATICS
CODE: 346/18/S08
DURATION: 140 HOURS

attitudes required to apply mathematical principles in solving engineering related
problems.
By the end of the subject content, the student should be able to:
2.1 perform basic calculations in various number system
2.2 perform basic arithmetic and algebra calculations
2.3 define a function and its derivatives
2.4 demonstrate knowledge of rules of indices, standard form, and rules of
algorithms
2.5 calculate area, volume, capacity, mass and specific gravity and ratios
2.6 define trigonometric functions and their properties
2.7 illustrate the relationship of algebraic equations and associated graphs
2.8 perform basic integration with applications
2.9 demonstrate knowledge of matrices
3.0 TOPICS
A. Number Systems
B. Laws of Arithmetic and Algebra, Rules of Precedence, Evaluation and
Transposition of Formulae, Multiplication and Division of Algebraic Polynomials
Factorisation by Common Factors, by Grouping and Quadratic Functions and
Polynomial Equations
C. Function Notation, Evaluation of a Polynomial by Nesting, Cubic and Quartic
Expressions Having Linear Factors
D. Rules of Indices, Standard Form, Preferred Standard Form, Rules of Logarithms,
Common Logarithms, Change of Base, Natural (Napierian) Logarithm and
Indicial Equations
E. Areas, Volumes, Capacity, Mass and Specific Gravity and Ratios
F. Angles and Trigonometry
G. Co-ordinate Geometry and Introduction to Differentiation
H. Integration the Reverse of Differentiation, Constant of Integration and Indefinite
Integrals
I Definitions, order, Types of Matrices, Addition and Subtraction of Matrices,
Multiplication of Matrices and Solution of Simultaneous Equations Using
Matrices
44
4.0 CONTENT
4.1 NUMBER SYSTEMS
4.1.1 Define natural, real, rational and irrational numbers.

4.1.2 Solve problems relating to approximation.
- Round off the numbers to the required decimal place.
- Round off the numbers to the required significant figure.
4.1.3 Solve problems relating to number systems.
- Convert the numbers to denary, binary, octal, duodecimal and hexadecimal
systems.
- Express denary numbers into octal, binary and hexadecimal form through the
use of octals as an intermediate step.
4.2 LAWS OF ARITHMETIC AND ALGEBRA, RULES OF PRECEDENCE,

EVALUATION AND TRANSPOSITION OF FORMULAE, MULTIPLICATION
AND DIVISION OF ALGEBRAIC POLYNOMIALS FACTORISATION BY
COMMON FACTORS, BY GROUPING AND QUADRATIC FUNCTIONS AND
POLYNOMIAL EQUATIONS
4.2.1 Solve problems pertaining to laws of arithmetic and algebra.

- Define and apply cumulative, associative and distributive laws to solve
Mathematical problems.
- Use rules of precedence (BODMAS) in simplifying Arithmetic expressions
4.2.2 Understand the basic rules of solving problems and relating to equations and
transposition.
- Define an equation.
- Construct equations of letters and numbers.
- State and apply rules of equations.
- Distinguish between an expression and equation.
- Relate equations to formulae.
- Transpose formulae relating to Motor Vehicle Technology and Science.
4.2.3 Simplify algebraic expression relating multiplication and division of polynomials.
Evaluate algebraic expressions involving:
- Whole number indices.
- Fractional indices.
- Decimal indices.
4.2.4 Solve problems relating to the factorisation of algebraic expressions.
- Multiply an algebraic expression of a single variable.
- Divide an algebraic expression by another.
- Factorise algebraic expressions by common grouping and difference of two
square.
- Factorise quadratic expressions
- Determine whether the quadratic expression is a perfect square.
4.2.5 Solve problems relating to linear equations and simultaneous linear equations.
- Find solutions to simultaneous equations by substitution.
45
- Find solutions to linear equations with two unknowns by equating
coefficients.
- Find solutions to linear equations with three unknowns.
4.2.6 Solve problems relating to quadratic equations.
- Find solutions to quadratic equations by using factors.
- Find solutions to quadratic equations by completing the square.
- Find solutions to quadratic equations by using the quadratic formula.
4.3 FUNCTION NOTATION, EVALUATION OF A POLYNOMIAL BY NESTING,

CUBIC AND QUARTIC EXPRESSIONS HAVING LINEAR FACTORS
4.3.1 Evaluate polynomial expressions.

- Define function notation.
- Define polynomial function.
4.3.2 Apply the “nesting” method to various polynomial expressions.
- Evaluate polynomial expressions by “nesting” method.
4.3.3 Apply the Remainder theorem and Factor theorem to evaluate polynomial
expressions.
4.3.3 Apply either Remainder theorem or Factor theorem to evaluate the polynomial
expressions.
- Factorise cubic and quadratic expressions having linear factors.
4.4 RULES OF INDICES, STANDARD FORM, PREFERRED STANDARD FORM,

RULES OF LOGARITHMS, COMMON LOGARITHMS, CHANGE OF BASE,
NATURAL (NAPIERIAN) LOGARITHM AND INDICAL EQUATIONS
4.4.1 Solve the problems relating to indices.

- Define an index.
- State the parts of an index.
- State the rules of indices.
- Apply the rules of indices to simplify expressions.
- Express numbers in standard form.
- Evaluate expressions in standard form.
- Evaluate expressions in preferred standard form.
4.4.2 Solve the problems relating to logarithms.
- Define logarithms.
- State the parts of logarithm.
- Apply the rules of algorithms to simplify expressions.
- Convert logarithms to anti-logarithms.
- Convert a base of logarithms to another form.
- Convert numbers to natural (Napierian) logarithms.
- Apply the rules of logarithms to solve indical equations
46
4.5 AREAS, VOLUMES, CAPACITY, MASS AND SPECIFIC GRAVITY AND
RATIOS
4.5.1 Solve problems relating to Areas, Volume, Capacity, Mass and specific gravity:
a) Solve problems of:
- Areas of circles
- Annulus
- Cone
- Sphere
- Hemisphere
- Ellipse
b) Sketch the figures mentioned in (a) above and state the formulae for
finding their areas.
c) Calculate the volumes of a:
- Cylinder
- Cube
- Hollow cylinder
- Sphere
- Cone
d) Solve problems pertaining to engine and transmission systems by
calculating:
- Swept volume
- Total volume
- Clearance volume
- Compressions ratios
- Camshaft drives
- Air-fuel ratio
- Gear ratios (manual gearbox, final drive to include differential)
- Belt drive ratios in relation to gear ratios.
e) Define:
- Mass
- Specific gravity
- Relative density
4.6 ANGLES AND TRIGONOMETRY
Identify types of properties of triangles and angles and solve problems relating to them.
4.6.1 State and sketch types of angles.
4.6.2 Describe and identify the different angles.
4.6.3 Define a triangle.
4.6.4 List, describe and sketch types of triangles:
- Acute angled
- Right angled
- Obtuse angled
- Equilateral
- Isosceles
47
4.6.5 Solve problems involving Right Angled triangles using Pythagoras’ Theorem and
Trigonometrically ratios of sine, cosine, tangent and cotangent.
4.6.6 Convert radians to degrees and vice-versa.
4.6.7 Determine the length of a given arch from the angle formed at the arc centre and
vice-versa.
4.6.8 Solve angular problems concerning:
- Valve timing
- Injection and ignition timing.
4.6.9 Calculate:
- Piston travel
- Angle of obliquity
- Crank angle
Using sine and cosine formulae.
4.6.10 Solve angular problems concerning steering geometry and taper angle and length
on given tapered shaft.
4.6.11 Solve problems involving angles of elevation and depression.
4.7 CO-ORDINATIONATE GEOMETRY AND INTRODUCTION TO

DIFFERENTIATION
4.7.1 Understand the principles of co-ordinate geometry (Cartesian co-ordinates) in a

horizontal plane.
- Specify a definite point in a horizontal plane.
- Calculate the length of a straight line.
- Calculate the mid-point of a straight line.
- Calculate the slope or gradient of a straight line.
- Find the equation of a tangent of a curve at a point.
- Sketch straight line graphs.
- Sketch quadratic graphs (use of maxima and minima).
4.7.2 Understand the basic principles of differentiation.
- Determine the slope of a curve algebraically.
- Differentiate coefficients of powers of x and polynomials only.
- Determine the velocity and acceleration through the use of differentiation at a
particular time.
4.8 INTEGRATION THE REVERSE OF DIFFERENTIATION, CONSTANT OF

INTEGRATION AND INDEFINITE INTEGRALS
Understand the basic principles of integration.

4.8.1 Determine indefinite integrals of polynomial
4.8.2 Determine the constant (c) of integration.
48
4.9 DEFINITIONS, ORDER, TYPES OF MATRICES, ADDITION AND
SUBTRACTION OF MATRICES, MULTIPLICATION OF MATRICES AND
SOLUTION OF SIMULTANEOUS EQUATIONS USING MATRICES
4.8.1 Solve problems pertaining matrices.

- Define a matrix.
- State the types of matrices.
- Denote a matrix by a notation.
4.8.2 Evaluate matrices.
- Perform the addition and subtraction of matrices.
4.8.3 Perform the multiplication of matrices by:
- Scalar.
- Two matrices.
4.8.4 Solve the simultaneous equations with two and three unknowns using the
matrices.
5.0. MODE OF ASSESSMENT
MODE OF ASSESSMENT
EXAMINABLE WRITTEN COURSEWORK TOTAL
SUBJECTS EXAMINATION ASSESSMENT 60%
40%
Engineering Mathematics 3 hour paper A minimum of:
(346/18/S08) 100%
2 Assignments 20%
2 Practical Assignments
20%
2 Tests 20%
49
TOPIC No. TOPICS WEIGHTING %

1 Number systems 5
2 Laws of Arithmetic and Algebra rules of precedence, 5
evaluation and transposition of formulae, multiplication
and division of algebraic polynomials factorisation by
common factors, by grouping and quadratic functions
and polynomial equations
3 Function notation, evaluation of a polynomial by 5
nesting, cubic and quartic expressions having linear
factors
4 Rules of indices standard form, preferred standard 10
form, rules of logarithms, common logarithms, change
of base, natural (Napierian) logarithm and indical
equations
5 Areas, volumes, capacity, mass and specific gravity 10
and ratios
6 Angles and trigonometry 15
7 Co-ordinate geometry and introduction to 15
differentiation
8 Integrate the reverse of differentiation, constant of 20
integration and indefinite integrals
9 Definitions, order, types of matrices, addition and 15
subtraction of matrices, multiplication of matrices and
solution of simultaneous equations using matrices
TOTAL 100%
7.0 SUGGESTED BOOKS FOR REFERENCE
1. Greer A. et al (2018) Tables, data & formulae for London Stanley

Engineers Thorne
2. Hurst J. (2016) Motor Vehicle Craft Studies London MacMillan
Part 2: Engines & Electrics
3. Kett P. W. (2017) Motor Vehicle Science Part London Chapman &
Two Hall
4. Moore G. (2015) Practical Problems in Albany, Delmar
Mathematics: For NY
Automotive Technicians
5. Pritchard (2016) General Course Workshop London Hodder &
R.T. Processes & Materials Staunton
6. Stroud K.A. (2015) Engineering Mathematics Hampshire MacMillan
Press
50
SUBJECT: ENGINEERING SCIENCE
CODE: 346/18/S09
DURATION: 140 HOURS

attitudes required to apply scientific principles in solving engineering related problems.
At the end of covering the subject content, the student should be able to:
2.1 describe vector/scalar quantities
2.2 demonstrate knowledge of linear and angular motion
2.3 calculate forces
2.4 calculate moments
2.5 solve problems involving quantities of work
2.6 solve problems involving quantities of power
2.7 apply heat and thermodynamics principles
2.8 explain friction on a horizontal plane
2.9 demonstrate knowledge of strain and stress
2.10 describe types of machines
3.0 TOPICS
a. Introduction of Scalar and Vector Quantities, Vector Representation, Two Equal

Vectors, Types of Vectors, Addition of Vectors and Components of a Given
Vector
b. Linear and Angular Motion
c. Forces
d. Moments
e. Work
f. Power
g. Heat and Temperature
h. Friction on a Horizontal Plane
i. Stress and Strain
j Machines
51
CONTENT
4.1 INTRODUCTION OF SCALAR AND VECTOR QUANTITIES, VECTOR

REPRESENTATION, TWO EQUAL VECTORS, TYPES OF VECTORS,
ADDITION OF VECTORS AND COMPONENTS OF A GIVEN VECTOR
4.1.1 Differentiate between a scalar and vector quantity.

4.1.2 Denote a vector by a notation.
4.1.3 State types of vectors.
4.1.4 Perform addition of vectors (without proofs).
4.2 LINEAR AND ANGULAR MOTION
4.2.1 a) Describe the relationship between distance, time and speed and state their
SI units.
b) Describe velocity as a vector quantity.
c) Develop formulae for distance, time and speed for both linear and angular
motion.
d) Calculate distances covered by vehicles for given speeds and times.
e) Represent distance covered by a motor vehicle by velocity-time graphs
and also represent velocity by distance-time graphs.
f) Define linear and angular acceleration and deceleration and state their
formulae.
g) Solve problems involving:
- Linear and angular acceleration and deceleration.
- Braking distance.
- Braking efficiency.
h) State Newton’s three Laws of motion.
i) Solve problems pertaining to Newton’s Laws of motion.
4.2.2 a) State factors affecting
- Braking distance and
- Braking efficiency
b) Distinguish between uniform velocity and variable velocity.
4.3 FORCES
4.3.1 Define Force and Vector and Polar quantities.

4.3.2 Differentiate between equilibrant and resultant.
4.3.3 Describe forces in a straight line.
4.3.4 Define triangle of forces.
4.3.5 Describe “Bow’s Notation” with reference to Space and Vector diagrams.
4.3.6 Solve problems involving triangle of forces graphically.
4.37 Define “Parallelogram of Forces”.
4.3.8 Solve problems involving parallelogram of forces, graphically.
4.3.9 Resolve forces into vertical and horizontal components graphically as well as
using trigonometry.
52
4.3.10 Carry out experiments to prove triangle and parallelogram of forces theories.
4.4 MOMENTS
4.4.1 State types of levers.

4.4.2 Describe each type of lever and sketch it.
4.4.3 Define:
- Moment of a force.
- Turning moment.
- Torque.
- Fulcrum.
- Pivot.
4.4.4 State the principle of moments and conditions for equilibrium.
4.4.5 Solve problems on simple levers.
4.4.6 Solve problems on bell-crank levers.
4.4.7 State and explain Newton’s 3rd law of motion – “To every action there is an
equal and opposite reaction”.
4.4.8 Name common engineering applications of the law in (4.13.7) above.
4.4.9 Solve problems involving Reaction on Beams.
4.4.10 Define Centre of Gravity.
4.4.11 State ways of determining Centre of Gravity.
4.4.12 Determine Centre of Gravity
- By calculation.
- By experiment.
4.4.13 Explain the importance of knowing the position of Centre of Gravity when
lifting and transporting loads.
4.5 WORK
4.5.1 State the SI units for work done, force and torque.
4.5.2 Define work as a form of energy.
4.5.3 State the formulae for work done in a straight line and on an incline.
4.5.4 Solve problems involving work done in straight line and against gravity
4.5.5 Define Tractive effort and resistance.
4.5.6 Solve problems involving Tractive effort and resistance.
4.5.7 Define work done in rotation.
4.5.8 Relate work done in rotation to motor vehicles.
4.5.9 Calculate the turning effect of forces for given situations.
4.5.10 Represent work done on force – distance graphs.
4.5.11 Explain pressure-volume diagrams (Indicator diagrams for both petrol and
diesel).
53
4.6 POWER
4.6.1 Define power.

4.6.2 State the SI unit for power.
4.6.3 Relate the Watt to the horse power.
4.6.4 Solve simple problems involving power (work done and time taken).
4.6.5 Describe how power is produced in the engine cylinder.
4.6.6 Define:
- Indicated power.
- Brake power.
4.6.7 Calculate indicated power produced by:
- One cylinder.
- Entire engine.
4.6.8 Calculate brake power out through engine flywheel.
4.6.9 Describe determination of power by the Farnborough indicator.
4.6.10 Describe and explain the Morse test procedure.
4.6.11 Determine:
- Indicated power.
- Brake power.
- Torque.
- Friction power.
4.6.12 Calculate the mechanical efficiency of an engine.
4.6.13 Interpret Morse test results.
4.6.14 Determine power produced by a motor vehicle using a rolling road tester.
4.7 HEAT AND TEMPERATURE
4.7.1 Define heat as a form of energy.

4.7.2 State the SI unit of heat.
4.7.3 State the effects of heat on materials:
- Shape.
- Size.
- Condition.
- Composition.
- Colour.
4.7.4 State the electrical effect of heat on materials.
4.7.5 Give examples of each of the effects in 14.16.3 on Motor Vehicles.
4.7.6 Describe the methods of heat transfer with reference to Motor Vehicles.
4.7.7 Explain measurement by heat by:
- Conduction.
- Temperature gauges on engines.
- Pyrometer.
4.7.8 Name metric and imperial temperature scales.
4.7.9 Convert to ; to K and vice versa.
4.7.10 Describe a Mercury-in-Glass thermometer.
54
4.7.11 Explain effects of freezing points on diesel, petrol, electrolyte, brake-
fluid, oils, water in radiator, etc.
4.7.12 Determine the quantity of heat in materials using various methods.
4.7.13 Explain specific heat capacity.
4.7.14 State factors affecting the quantity of heat in a body.
4.7.15 Explain the law of conservation of energy (heat gained = heat lost) with
reference to water-cooled systems.
4.7.16 Solve problems involving heat lost and heat gained by materials.
4.7.17 Describe and explain change of state of substances.
4.7.18 Construct a temperature – time graph of substance changing state.
4.7.19 Define latent and sensible heat with reference to change of state of
quantity of heat.
4.7.20 Explain Calorific value of a fuel with reference to first grade and
second grade diesel fuel.
4.7.21 Calculate the Calorific value of a given fuel or substance.
4.7.22 Describe co-efficient of linear, superficial and cubical expansion.
4.7.23 Solve problems involving linear expansivity.
4.7.24 Compare materials’ expansion rates.
4.7.25 Select materials for use on vehicles taking consideration of the
expansion rate.
4.8 FRICTION ON A HORIZONTAL PLANE
4.8.1 Define friction.

4.8.2 State and describe the under-listed types of friction:
- Boundary.
- Dry.
- Fluid.
4.8.3 State factors affecting frictional resistance on two materials (one sliding
over the other).
4.8.4 State and explain laws of friction.
4.8.5 Prove frictional laws by experiment.
4.8.6 Solve problems involving frictional resistance, coefficient of friction
and load.
4.8.7 Describe and explain friction in bushed and shell bearings.
4.8.8 Solve problems involving frictional torque in bearings (Shell and Bush).
4.8.9 Describe torque transmission by a clutch.
4.8.10 State factors affecting torque transmitted by a clutch.
4.8.11 Solve problems involving torque transmitted by a clutch.
4.8.12 Calculate clutch safety factor.
4.8.13 Explain effect of intensity of pressure on clutch friction material.
4.8.14 Describe effects of lubricants on frictional surfaces.
4.8.15 Explain requirements for Extreme Pressure (EP) or Hypoid oil types
for heavy loads.
55
4.9 STRESS AND STRAIN
4.9.1 Name the types of forces acting on motor vehicle equipment

4.9.2 Describe each of the forces listed in (4.18.1) above with aid of sketches.
4.9.3 Give examples of the forces named in (4.18.1) on a motor vehicle.
4.9.4 State the units and formula for stress.
4.9.5 Define strain as change in length:- Original length.
4.9.6 State the effects of overloading on materials.
4.9.7 Solve problems involving stress and strain.
4.9.8 State the relationship between stress and strain.
4.9.9 Carry out experiments on the relationship between Force and Extension.
4.9.10 Describe the following points:
- Limit of proportionality.
- Maximum load.
- Yield point.
- Elastic limit.
- Fracture load.
4.9.11 State elastic limits for materials normally used in engineering.
4.9.12 Solve problems relating to Young’s Modulus.
4.9.13 Explain importance of safety factor on materials.
4.10 MACHINES
4.10.1 Define a machine.

4.10.2 Outline the history of machines.
4.10.3 Identify common types of machines
4.10.4 Describe principles of operation of machines mentioned in (4.10.3)
using drawings.
4.10.5 Define the following:
- Mechanical Advantage (MA).
- Velocity Ratio (VR).
- Mechanical Efficiency (ME).
4.10.6 Calculate the MA, VR and ME for the machines named in (4.10.3)
4.10.7 Describe basic principles of hydraulics.
4.9.8 Relate hydraulic theory to the hydraulic jack/press and as applied to
motor vehicles.
4.10.9 Calculate problems involving MA, ME and VR in hydraulic jacks.
4.10.10 Calculate power transmitted through the following:
4.10.11 Select pulleys suitable for shafts to run at given speeds.
4.10.12 Solve problems involving gearbox, steering box and final drive ratios.
56
5.0 MODE OF ASSESSMENT
MODE OF ASSESSMENT
40%
Engineering Science 3 hour paper A minimum of:
(346/18/S09) 100%
2 Assignments 20%
20%
2 Tests 20%
TOPIC No. TOPICS WEIGHTING%

1 Introduction of Scalar and Vector Quantities, Vector 5
Representation, Two Equal Vectors, Types of Vectors,
Addition of Vectors and Components of a Given Vector
2 Linear and Angular Motion 5
3 Forces 15
4 Moments 10
5 Work 10
6 Power 10
7 Heat and Temperature 15
8 Friction on a Horizontal Plane 10
9 Stress and Strain 10
10 Machines 10
TOTAL 100%
1. Greer A. et al (2018) Tables, data & formulae for London Stanley

Engineers Thorne
2. Hurst J. (2016) Motor Vehicle Craft Studies London MacMillan
Part 2: Engines & Electrics
3. Kett P.W. (2017) Motor Vehicle Science Part London Chapman &
Two Hall
57
SUBJECT: ENGINEERING DRAWING
CODE: 346/18/S04
DURATION: 180 HOURS
The aim of the subject is to equip the student with knowledge and skills of
communicating ideas and information in the automotive industry through engineering
drawing.
At the end of covering the subject content, the student should be able to:
2.1 interpret engineering drawings.

2.2 make drawings of components for use in industry.
2.3 draw basic engineering drawings.
2.4 apply principles of engineering drawing standards.
2.5 demonstrate knowledge of orthographic projection
2.6 explain basic assembly drawing
2.7 make pictorial presentation
2.8 demonstrate knowledge of circuit diagrams
2.9 demonstrate knowledge of conventional representation
2.10 practice CAD
3.0 TOPICS
3.1 Introduction to Engineering Drawing

3.2 Drawing Equipment
3.3 Lines and Lettering
3.4 Geometrical Construction and Dimensioning
3.5 Orthographic Projection
3.6 Basic Assembly Drawing
3.7 Pictorial Presentation
3.8 Circuit Diagrams
3.9 Conventional Representation
3.10 AutoCAD
58
4.0 CONTENT
4.1 INTRODUCTION TO ENGINEERING DRAWING

4.1.1 Define Engineering Drawing.
4.1.2 List the ways Engineering Drawing is used in automotive trades.
4.1.3 Explain the importance of presenting drawings in the required standards.
4.1.4 List the advantages of using drawings as a means of communicating technical
information.
4.1.5 List the types of Projection used in automotive engineering drawing.
4.1.6 Describe the selection process for standard paper and pencil grades.
4.1.7 Explain the use of scales in engineering drawing.
4.1.8 Copy to a given scale.
4.1.9 Explain the use of universal standards in Engineering Drawing.
4.2 DRAWING EQUIPMENT

4.2.1 List drawing equipment used in Engineering Drawing.
4.2.2 Describe the attributes that govern the selection of instruments and equipment
to be used for given drawings.
4.2.3 Demonstrate the proper use, care and maintenance of drawing instruments and
equipment, to include:
- Drawing boards.
- Tee-Square.
- Draughting Machine.
- Pens and Pencils.
- Scale rules.
- Stencils.
4.2.4 Explain the need for cleanliness in the drawing office.
4.2.5 Discuss the longevity of drawing depending on:
- Drawing Media (e.g. ink type).
- Drawing Fabric (paper, plastic film etc.).
- Exposure to various types of rays, heat ranges or chemicals.
4.3 LINES AND LETTERING

4.3.1 Identify types of lines used in engineering drawing.
4.3.2 State the uses of the different types of lines.
4.3.3 Draw examples of each line type.
4.3.4 Apply each type of line where appropriate.
4.3.5 List the requirements for different letter and number, sizes, and their types in
technical drawing.
4.3.6 Produce clear, uniform, freehand letters and numerical, applying the appropriate
lines and using the correct pencil type.
4.3.7 Produce bold lettering and numbering suitable for engineering drawing.
4.3.8 Illustrate the use of lettering and numbering in the production of the title blocks
used in engineering.
59
4.4 GEOMETRICAL CONSTRUCTION AND DIMENSIONING
4.4.1 LINES
Perform the listed geometrical activities:
- Bisect a line.
- Construct a perpendicular from a given point to a line.
- Divide a line into proportional parts.
- Construct a perpendicular from any point to a line
- Construct parallel lines.
4.4.2 ANGLES
- Define and identify types of angles.
- Bisect an angle.
- Construct various types of angles without a protractor.
- Copy an angle.
4.4.3 ARCS AND CIRCLES

- Define a circle and identify various parts of a circle.
- Find the centre of given arc or a circle.
- Construct geometrical shapes as required.
- Join straight lines to curves by an arc.
- Construct ellipse and scales.
4.4.4 DIMENSIONING
a) Apply rules of dimensioning to include:
- Functional and non-functional dimensions.
- Auxiliary Dimensions.
- Chain Dimensioning.
- Datum Dimensioning.
b) Allocate dimensions to working drawings following the BS 308 standard
(and local equivalent).
c) Use pencils for dimensioning.
4.5 ORTHOGRAPHIC PROJECTION
4.5.1 Describe and identify the difference between Isometric and Oblique Projection.
4.5.2 Describe and demonstrate automotive applications of isometric and oblique
projections.
4.5.3 FIRST ANGLE PROJECTION
a) Identify diagrams in Fist Angle Projection.
b) Construction simple Orthographic drawings in First Angle Projection,
using typical Motor Vehicle (Light and Heavy) application.
c) Select and use appropriate types of lines for drawing diagrams in
orthographic First Angle Projection to include:
- Hidden detail.
- Centre lines.
60
- Arcs and Curves.
d) THIRD ANGLE ORTHOGRAPHIC PROJECTION
- Produce orthographic projection drawings from pictorial drawings.
- Identify diagrams in THIRD Angle Projection.
- Describe and identify the difference(s) between FIRST & THIRD
Angle Projection.
e) FREEHAND SKETCHING
- Produce diagrams following the principles of freehand sketching.
- Sketch diagrams in First Angle Projection using freehand sketches.
f) ISOMETRIC PROJECTION
- Draw diagrams using Isometric Projection to include any angles
involved.
- Construct an ellipse and Isometric circles using given methods.
- Construct simple diagrams using the Isometric scale.
g) SECTIONING
- Describe rules of sectioning.
- Draw diagrams in First Angle Projection, applying the rules of
sectioning.
- Extend the principle of orthographic projection.
- Describe and identify components which must NOT be sectioned
generally or those which may not be sectioned under certain
circumstances.
h) CONVERSIONS
a) Convert diagrammatic representation into simple drawings of
mechanical components to include:
- Bars, Tubes and shafts.
- Compression and Tension springs.
- Splined and serrated shafts (both internally and externally)
b) Sketch and work from Datum.
4.5.4 BASIC ASSEMBLY DRAWING

4.5.4.1 Explain the following:
- Shape
- Size
- Specifications
- Location and relationship of all parts
4.5.4.2 Describe the elements of engineering procedure
4.5.4.3 Distinguish between types of drawings
61
4.6 PICTORIAL REPRESENTATION
4.6.1 Distinguish orthographic projection drawings from pictorial drawings.
4.6.2 Interpret orthographic projection drawings.
4.6.3 Convert orthographic projection drawings of mechanical components to pictorial
drawings.
4.6.4 Interpret conventional abbreviations and symbols on Automotive Engineering
drawings.
4.6.5 Interpret exploded diagrams of Motor Vehicle Mechanical components.
4.7 FURTHER ORTHOGRAPHIC PROJECTION

4.7.1 Interpret orthographic projection drawings of:
 Gearboxes (Manual and Automatic) to include P.T.O. systems.
 Differential Unit.
 Double-reduction hub
 Water pump.
 Clutch mechanisms.
 Carburettors.
 Timing Gear Assemblies.
 Crank and cam shafts.
 Fuel injectors and injector pumps.
 Various steering box types.
4.7.2 Convert orthographic drawings mentioned in 4.7.1 above to pictorial drawings.
4.7.3 Draw exploded diagrams of units mentioned in 4.7.1 above (where applicable).
4.8 CONVENTIONAL REPRESENTATION

4.8.1 Demonstrate the following:
 Threads.
 Interrupted views.
 Repeated parts.
 Splined and serrated shafts.
 Knurling.
 A square or a flat on a shaft.
 Holes on linear or circular pitch.
 Spur gears.
4.9 CIRCUIT DIAGRAMS

4.9.1 Hydraulic circuits
4.9.1.1 Interpret a tractor hydraulic circuit.
4.9.1.2 Identify by name all control units (i.e. valves, pumps, etc.).
4.9.1.3 Use hydraulic circuit symbols to graphically produce hydraulic circuits
used on light and heavy vehicles (i.e. Power steering, Power Brakes,
tipping, mechanisms etc.)
4.9.2 Pneumatic circuits
4.9.2.1 Read and interpret a basic heavy vehicle air brake circuit.
4.9.2.2 Identify all circuit units (e.g. Unloaders, compressor, filters, accumulators,
various valves, etc.).
62
4.9.2.3 Reproduce given pneumatic circuits on paper – using pneumatic –
appropriate circuit symbols.
4.9.3 Basic Electrical Circuits
4.9.3.1 Interpret basic auto-electrical circuits.
4.9.3.2 Identify basic units from given circuit diagrams.
4.9.3.3 Reproduce given basic auto-electrical circuits on paper using
convention symbols to represent system components.
4.10 AUTO CAD

4.10.1 Describe and explain methods of preparing Engineering Drawings using CAD
 User interface
 Customising user interface
 Auto Cad Commands
 Draw lines and shapes
 Use erase, undo and redo tools
 Draw entities using absolute and relative coordinate points
 Draw entities using the tracking method
 Use drawing aids
 Use editing tools
 Multi-view drawings
 Dimensions and annotation
 Sectional views
 Block, attributes and Xrefs
 Layout and annotative objects
 Templates and plotting
4.10.2 Use CAD to:
- Produce basic automotive related diagrams
- Plot and print drawing to scale
- Plot and print drawings to fit selected paper size.
5.0 MODE OF ASSESSMENT:
MODE OF ASSESSMENT
40%
Engineering Drawing 3 hour paper A minimum of:
(346/18/S04) 100%
2 Assignments 20%
20%
2 Tests 20%
63
TOPIC No. TOPICS WEIGHTING %
1 Introduction to Engineering Drawing 3
2 Drawing Equipment 2
3 Lines and Lettering 2
4 Geometrical Construction and Dimensioning 3
5 Orthographic Projection 20
6 Basic Assembly Drawing and Sectioning 20
7 Pictorial Presentation 10
8 Circuit Diagrams 5
9 Conventional Representation 5
10 AUTOCAD 30
TOTAL 100
1. Zammit (2010) Motor Vehicle Engineering London Longman

S.J. Drawing for Technicians:
Level One
2. Bland S. (2011) Graded Exercises in Johannesburg Longman
Technical Drawing.
3. Bosh (2010) Graphic Symbols and Stuttgart Bosch
GmbH Circuit Diagrams for
Automotive Electrics
64
SUBJECT NAME ENTREPRENEURIAL SKILLS DEVELOPMENT
CODE 402/19/S01
DURATION 80 Hours

The syllabus is designed to develop a culture of responsible and sustainable entrepreneurship in
students, equipping them with knowledge, attitudes and skills to run a business enterprise.

By the end of the course, the student should be able to:
2.1 produce students with relevant knowledge, attitudes and skills to run a small business
2.2 analyse the origins and causes of employment syndrome among indigenous Zimbabweans
2.3 assess the need to create employment for self and others as a first priority after graduation
2.4 generate a viable business plan
2.5 discuss the roles of management in a business
2.6 apply tips of customer care in a business environment
2.7 explain the importance of costing and pricing in running a business
2.8 describe the importance of record keeping and stock control in business
2.9 produce a marketing plan for a business
2.10 examine various business growth strategies
2.11 discuss the importance of risk covers in entrepreneurship
2.12 analyse the various legal statutory provisions applicable to business in Zimbabwe
2.13 discuss the importance of business ethics to an entrepreneur
3.0 TOPICS
 Entrepreneurship.
 Business Environment in Zimbabwe.
 Human Resources Management.
 Business Management.
 Customer Care.
 Costing and Pricing.
 Recording Keeping and Stock Control.
 Marketing.
 Risk Management.
 Business Ethics and Social Responsibility.
65
4.0 CONTENT
4.1 ENTREPRENEURSHIP
4.1.1 Define entrepreneurship.
4.1.2 Discuss the various concepts of Entrepreneurship.
4.1.3 Analyse the various forms of Business Ownership.
4.1.4 Outline the procedures in the formation of various business forms.
4.1.5 Identify the advantages and disadvantages of each of the business form.
4.2 BUSINESS ENVIRONMENT IN ZIMBABWE
4.2.1 Analyse the causes of the existence of the employment syndrome in indigenous
Zimbabweans.
4.2.2 Examine the history and culture of business ownership patterns in Zimbabwe.
4.2.3 Discuss the macro and micro environment factors affecting entrepreneurship in
Zimbabwe.
4.2.4 State the importance of a business plan to a business.
4.2.5 Generate a business plan.
4.3 HUMAN RESOURCES MANAGEMENT

4.3.1 Define human resources management.
4.3.2 Explain the human resources management process.
4.3.3 Discuss the importance of human resources management to the entrepreneur.
4.3.4 Outline theories of staff motivation in business.
4.4 BUSINESS MANAGEMENT

4.4.1 Define business management.
4.4.2 Explain the roles of management in a business e.g. Planning Organising, Leading and
Controlling.
4.4.3 Discuss the importance of computers as a business management tool (record keeping,
stock control, accounts, and production control).
66
4.5 CUSTOMER CARE
4.5.1 Define customer care.
4.5.2 Discuss ten tips of customer care.
4.5.3 Explain benefits of customer care to an entrepreneur.
4.6 COSTING AND PRICING

4.6.1 Define various costing and pricing terms.
4.6.2 Explain the importance of costing to a business.
4.6.3 Analyse the costing processes of a product in a business.
4.6.4 Calculate prices of products.
4.6.5 Describe pricing strategies.
4.7 RECORD KEEPING AND STOCK CONTROL

4.7.1 Define record keeping and stock control in business.
4.7.2 Describe the importance of record keeping and stock control.
4.7.3 Identify source business documents.
4.7.4 Explain the purpose of books of accounts (cash books, ledger, etc.)
4.7.5 Outline effective buying and stock control procedures.
4.8 MARKETING
4.8.1 Define marketing.
4.8.2 Devise a marketing plan for a business.
4.8.3 Discuss the marketing mix strategies.
4.8.4 Examine various business growth strategies.
4.9 RISK MANAGEMENT

4.9.1 Define risk management in business.
4.9.2 Discuss the importance of risk covers in entrepreneurship.
4.9.3 Explain the principles of risk management to a business.
4.9.4 Outline the steps involved in the risk management process.
4.9.5 Identify the various risk management strategies in business
67
4.10 BUSINESS ETHICS AND SOCIAL RESPONSIBILITY
4.11 Define business ethics and social responsibility.
4.12 Explain the importance of business ethics to entrepreneurs.
4.13 Outline social responsibility principles.
4.14 Explain the importance of social responsibility to the entrepreneur.

EXAMINATION 40% CONTINUOUS ASSESSMENT 60% %
1 3 hour written A minimum of
examination 2 Assignments 20%
100
2 Practical Assignments 20%
2 Tests 20%
68
6.0 ASSESSMENT SPECIFICATIONS GRID
Weighting 60% Coursework and 40% Examination (as per existing HEXCO rules and
regulations)
TOPIC % WEIGHTING
1 Entrepreneurship. 10
2 Business Environment in Zimbabwe. 10
3 Human Resources Management. 10
4 Business Management. 10
5 Customer Care. 10
6 Costing and Pricing. 10
8 Record Keeping and Stock Control. 10
7 Marketing. 10
9 Risk Management. 10
10 Business Ethics and Social Responsibility. 10
TOTAL 100%
69
7.0 PAPER STRUCTURE
Students should answer any 5 from a total of 9 questions. Each question carries 20 marks. Total
100 marks.
NUMBER OF WEIGHTING
QUESTIONS
Entrepreneurship and business environment 2 20%
Human resources management, Business Ethics and Social 2 20%

Responsibility
Business management and risk management 2 20%
Marketing and customer care 1 20%
Costing and pricing, record keeping and stock control 2 20%
TOTAL 9 100%
8.0 REFERENCES
1. Hisrich. R. D. and Peters M. P. (2016) Entrepreneurship Tatq McGraw Hill New Delphi
2. Holt, D T. (2017) Entrepreneurship Prentice Hall London
3. Jarskoy H. and Stevenson D. (2014) International labour organisation start Your Business.
ILO. Harare
4. Marcouse, I. (2016) Business studies 2nd Ed Hodder Arnold. London
5. McGuckin F. (2014) Business for beginners: Step by Step to start your new business
East Leigh Management services. London
6. Need Harm D and Dransfield R (2000) Advanced Business and Dexel Oxford
7. Stoner J.A.F; Freeman. R.E. and Gilbert. D. R. JR. (2017) Management 6th Edition
Prentice Hall International Englenwood Cliffs. New Jersey.
8. Zimmerer T. W. and Scaborough, N. M. (2015) Essentials of Entrepreneurship and small

business Management Prentice Hall. New Delhi
70
SUBJECT NAME NATIONAL STUDIES
CODE 401/19/S01
DURATION 80 Hours

The subject is designed to cultivate values of patriotism, national identity, national unity and
commitment to sustainable national development.

By the end of the programme, the student should be able to:
2.1 demonstrate patriotism
2.2 analyse the socio-economic and political structures of pre-colonial societies in relation to the
development of Zimbabwe
2.3 discuss the causes, prosecution and results of the First and Second Chimurenga
2.4 evaluate post-colonial socio-economic and political development policies put in place to
correct colonial imbalances
2.5 examine Zimbabwe’s cultural elements and natural resources on sustainable development of
the economy
2.6 discuss the importance of regional and international relations to Zimbabwe’s socio-economic
and political development
2.7 explain the law-making process and the role of the constitution
2.8 exhibit an understanding of the legal framework in Zimbabwe
2.9 demonstrate an appreciation of the conflict transformation and resolution styles.
3.0 TOPICS
 Civic education
 Culture and heritage
 Pre and colonial Zimbabwean history
 Post-colonial Zimbabwe
 Legal and parliamentary studies
 Regional and international relations
 Conflict transformation and resolutions
71
4.0 CONTENT
4.1 Civic education
4.1.1 Define civic education.
4.1.2 Outline the background to the introduction of National Studies.
4.1.3 Explain the importance of National Studies to the sustainable development of Zimbabwe
4.2 Culture and heritage

4.2.1 Define culture and heritage.
4.2.2 Explain the importance of cultural heritage elements of the Zimbabwean people
4.2.3 Demonstrate aspects of multicultural diversity and development amongst Zimbabweans.
4.2.4 Examine the importance of natural resources to the Zimbabwean community
4.2.5 Discuss the impact of the natural resources and heritage to the development of
Zimbabwe.
4.3 Pre and colonial Zimbabwean history
4.3.1 Analyse pre-colonial societies’ socio-economic and political structures.
4.3.2 Diagnose the impact of pre-colonial systems and civilisation on development of
Zimbabwe
4.3.3 Compare and contrast pre-colonial societies and present-day societies.
4.3.4 Assess the various reasons for the colonisation of Zimbabwe.
4.3.5 Analyse the causes and the major events of the First and Second Chimurenga
4.3.6 Examine the results of the two struggles.
5.3 Post-Colonial Zimbabwe
5.3.1 Outline the socio-economic and political policies implemented by the government of
Zimbabwe since 1980.
5.3.2 Analyse the background and causes to the Third Chimurenga.
5.3.3 Examine the periodical holding and importance of elections in Zimbabwe from 1980 to
date.
5.5 Legal and Parliamentary Studies
5.5.1 Define law.
5.5.2 Explain the origins of law.
5.5.3 Analyse the law-making process in Zimbabwe.
5.5.4 Evaluate the three arms of the state.
5.5.1 Examine the provisions of the Constitution of Zimbabwe.
72
5.6 Regional and International Relations
5.6.1 Define regional and international relations.
5.6.2 Identify the 3C’s to International relations.
5.6.3 Classify the functions of diplomatic missions.
5.6.4 Examine the role of non-governmental organisations (NGOs) in the countries they
operate in.
5.6.5 Assess Zimbabwe’s foreign policy.
5.6.6 Evaluate the impact of creditors on the development of Zimbabwe.
5.6.7 Analyse the importance of media to the development of Zimbabwe.
5.7 Conflict transformation and resolutions

5.7.1 Explain the various causes of conflict.
5.7.2 Analyse African traditional conflict resolution methods used during the pre-colonial
times.
5.7.3 Outline Conflict management and resolution styles.
5.7.4 Discuss the strategies for sustaining peace.

EXAMINATION 40% CONTINUOUS ASSESSMENT 60% %
1 3 hour written examination A minimum of

2 Assignments 20%
2 Practical Assignments 20% 100
2 Tests 20%
73
7.0 ASSESSMENT SPECIFICATIONS GRID
SECTION A: ZIMBABWE HISTORY AND CULTURE (40%)
Civic education, culture and heritage and Zimbabwe History.
SECTION B: LEGAL AND PARLIAMENTARY STUDIES (20%)

Law, origins and purposes, arms of the state and provisions of the constitution of
Zimbabwe.
SECTION C: REGIONAL & INTERNATIONAL RELATIONS (20%)
The nature of international relations, regional organisations, public international

organisation, global politics, Zimbabwe’s foreign policy development, international
economic relations, international capital and Imperialism, the role and functions of the
media
SECTION D: CONFLICT TRANSFORMATION AND RESOLUTIONS (20%)

Causes of conflict, African traditional conflict resolution methods, conflict
management and resolution styles, strategies for sustaining peace.
74
8.0 PAPER STRUCTURE
Students should answer any 5 from a total of 9 questions. Each question carries 20 marks. Total
100 marks.
NUMBER OF WEIGHTING
QUESTIONS
Civic education, culture & heritage and Zimbabwe history 3 40%
Law, origins and purposes, arms of the state and provisions 2 20%
of the constitution of Zimbabwe
The nature of international relations, regional organisations, 2 20%

public international organisations, global politics,
Zimbabwe’s foreign policy development, international
economic relations, International capital and imperialism
and the role and functions of the media.
Causes of conflict, African traditional conflict resolution 2 20%

methods,
Conflict management and resolution styles,
strategies for sustaining peace.
TOTAL 9 100%
75
9.0 REFERENCES
9. Banerjee A. E. (2017), Poor Economics: A Radical Rethinking of the Way to Fight

Global Poverty
10. Beach D. N. (1986) War and Politics in Zimbabwe 1840-1900. Mambo Press: Gweru
11. Bhebhe N. & Ranger O. (1995) Society in Zimbabwe’s Liberation War. Volume2.
University of Zimbabwe Publications: Harare
12. Booth, D. & Diana C. (2015) (latest edition) "From Good Governance to Governance that
Work." In: David Booth & Diana Cammack Governance for Development in Africa.
Solving Collective Action Problems. London: Zed Books, 25 pages.
13. Brett, E. A. (2017) (latest edition) Reconstructing Development Theory. International

inequality, institutional reform and social emanicipation. London: Palgrave Macmillan,
80 pages. (also used in module 3)
14. Christie R. H. (1998). Business law in Zimbabwe. 2nd ed. Kenwyn: Juta: Pretoria
15. Collier, P. (2016) The Bottom Billion: Why the Poorest Countries are Failing and What
Can Be Done About It
16. Conteh M. E. (2015) (latest edition) Collective political violence: An introduction to the
theories and cases of violent conflicts. New York: Routledge, 200 pages.
17. Easterly, W. (2017) The Elusive Quest for Growth: Economists' Adventures and
Misadventures in the Tropics
18. Evans, P.B. (2018) (latest edition). "Constructing the 21st century democratic
development states: potentialities and pitfalls." In: Omano Edigheji (eds.) Constructing a
democratic developmental state in South Africa: potentials and challenges. Cape Town,
South Africa: HSRC Press, 26 pages.
19. Hisrich. R. D. and Peters M P (2012) Entrepreneurship Tatq McGraw Hill New Delphi
20. Holt, D. T. (2007) Entrepreneurship Prentice Hall London
76
21. Jarskoy H. and Stevenson D. (2010) International labour organisation start Your Business.
ILO. Harare
22. Kenny, C. (2016) Getting Better: Why Global Development Is Succeeding-And How We
Can Improve the World Even More
23. Kriesberg, L. & Bruce D. (2013). Constructive Conflicts: From Escalation to Resolution.
Lanham: Rowman & Littlefield, 408 pages.
24. Mallaby, S. (2017) The World's Banker: A Story of Failed States, Financial Crises, and
the Wealth and Poverty of Nations
25. Mandaza I. (1980) Zimbabwe: The Political Economy of Transition1980- 1986.Codesria

Book Series: London
26. Marcouse, I, Gillspie, A, Martin, B Malcolm S. and Wall N. (2016) Business studies 4th
Ed Hodder Arnold. London
27. McGuckin F. (2010) Business for beginners: Step by Step to start your new business
East Leigh Management services. London
28. Mkandawire, T. (2016) (latest edition) "From maladjusted to democratic development

states in Africa." In: Omano Edigheji (eds.) Constructing a democratic developmental
state in South Africa: potentials and challenges Cape Town, South Africa: HSRC Press,
25 pages.
29. Mudenge S. G. (2014), 3rd Edition, a Political History of Munhumutapa -1400-1902.

Zimbabwe Publishing House: Harare
30. Nabudere D. W. (1989) the Crash of International Finance Capital & Its Implications for
the 3rd World Countries. Sapes: Harare
31. Need Harm D. and Dransfield R. (2012) Advanced Business and Dexel Oxford
32. Rodney W. (1981) How Europe Underdeveloped Africa. Revised edition. Howard
University Press: Washington
77
33. Rodrik, D. (2017) The Globalization Paradox: Democracy and the Future of the World
Economy
34. Stoner J.A.F; Freeman. R.E. and Gilbert.D.R.JR (2014) Management 6th Edition Prentice
Hall International Englenwood Cliffs. New Jersey.
35. Todaro M. P. (2014) Economic Development 7th Edition Addison Wersley: London
36. Zimbabwe: Constitution of Zimbabwe amendment (no.20) Act 2013
37. Zimmerer T. W. and Scaborough, N. M. (2010) Essentials of Entrepreneurship and small

business Management Prentice Hall.NewDelhi
38. Zvobgo C. J. M. (1996) A History of Christian Missionaries in Zimbabwe1890-1939.

Mambo Press: Gweru
78
SUBJECT TITLE COMMUNICATION
SUBJECT CODE 346/19/S10
DURATION 80 HOURS

The aim of the subject is to strengthen the student’s ability to develop an awareness of
the importance of communication in the Automotive Industry.
By the end of the subject students should be able to:-

2.1.1 apply communication skills to enhance performance in the industry.
2.1.2 produce the necessary documentation
2.1.3 organise business meetings
1.1.4 prepare requisitions, workshop and log book records
2.1.5 produce job cards
3.0 TOPICS
3.1 Introduction To Communication
3.2 Language
3.3 Summary And Comprehension
3.4 Spoken Communication
3.5 Meetings
3.6 Business Letters
3.7 Reports
3.8 Business Organisations
3.9 Legislation Affecting Employers And Employees
3.10 Basic Stores Management
79
4.0 CONTENT
4.1 INTRODUCTION TO COMMUNICATION

Understand the communication model and write standardized letters, reports and
memoranda.
a) Define communication.
b) State the meaning of each of the following in the communication model:
i. Sender
ii. Encoding
iii. Channel/medium
iv. Receiver
v. Decoding
vi. Feed back
c) Describe the channels of communication.
d) Describe each of the following communication methods:
i. Letters
ii. Memorandum
e) Reports
a) State the barriers to effective communication.
4.2 LANGUAGE
4.2.1 Construct sentences and paragraphs.

4.2.2 Define linguistic abuse.
4.2.3 Identify style and tone.
4.2.4 Use appropriate business terms.
4.2.5 Use reference books.
80
4.3 SUMMARY AND COMPREHENSION
4.3.1 Pick out the important facts in a passage

4.3.2 Summarise passage
4.3.3 Explain terms out of context.
4.4 SPOKEN COMMUNICATION
4.4.1 Use the telephone

4.4.2 Pronounce and enunciate.
4.4.3 Talk audibly.
4.4.4 Appreciate the use of verbal communication in:
- Interviews
- Appraisal
- Reward
- Counselling
- Grievances
- Reprimands
- Dismissal
- Termination
4.5 MEETINGS
4.5.1 Explain the following:
4.5.1.1 Formal (private/public) meetings.
4.5.1.2 Committee meetings
4.5.1.3 Command meetings
4.5.1.4 Convene the meetings in 4.5.1.3
4.5.1.5 Write notices, agenda and minutes.
4.5.1.6 Explain the procedures of meetings.
4.5.1.7 Define the role of the:
- Chairperson
- Secretary
- Treasurer
81
4.6 BUSINESS LETTERS
4.6.1 Classify business letters.
4.6.2 Write:
- Person to firm.
- Firm to person
- Firm to firm
- Inquiry letter
- Quotation letter
- Order letter
- Delivery letter
- Collection letter
- Memorandum
- Complaint and adjustment letter.
4.6.3 Prepare curriculum vitae.
4.7 REPORTS
4.7.1 Write the following reports:
4.7.1.1 Progress/routine reports.
4.7.1.2 Technical reports
4.7.1.3 Recommendatory reports.
4.7.1.4 Accident reports.
4.8 BUSINESS ORGANISATIONS

4.8.1 Describe the contribution of the departments to the enterprise as a whole.
4.8.2 Describe the role of the division of labour.
4.8.3 Appreciate the need for co-operation flow of information, communication and feedback
between departments.
4.8.4 Appreciate the role of leadership styles, work ethics and human relations to the success of
the enterprise.
4.9 LEGISLATION AFFECTING EMPLOYERS AND EMPLOYEES

 Health and Safety Act
 Factories Act
 Workman’s Compensation Act
82
4.10 BASIC STORES MANAGEMENT
4.10.1 Differentiate between equipment, tools, consumables and working capital.

4.10.2 Explain the purpose of requisition and ordering procedures.
4.10.3 Appreciate the need for material, handling and storage specifications.
4.10.4 Understand the effect of depreciation on equipment, capital equipment and the
flow of production.
4.10.5 Prepare workshop and log book records.
4.10.6 Prepare job cards.
EXAMINABLE EXAMINATION CONTINUOUS WEIGHTING

SUBJECTS 40% ASSESSMENT
60%
Communication 3 hour A minimum of: 100%

346/19/S10 Theory paper
2 Assignments 20%
2 Practical
Assignments 20%
2 Tests 20%
83
6.0 ASSESSMENT GRID
TOPIC WEIGHTING PAPER

% WEIGHTING
THEORY PAPER
SECTION A [50 marks] Short questions THEORY PAPER
Answer All Questions 100%
1. Introduction To 5
Communication
2. Language 5
3. Spoken Communication 5
4. Business Letters 5
5. Reports 5
6. Business Organisations 5
7. Legislation Affecting
Employers And Employees 10
8. Basic Stores Management 10
84
% WEIGHTING
THEORY PAPER
Communication
2. Language 5
5. Reports 5
SECTION B [50 Marks]

Answer Any 5 Questions out of the
given 7
1. Introduction To
5
Communication
5
2. Language
3. Summary And
10
Comprehension
5
4. Spoken Communication
10
5. Meetings
5
6. Business Letters
10
7. Reports
10
8. Business Organisations
10
Employers And Employees
20
% WEIGHTING
THEORY PAPER
Communication
2. Language 5
5. Reports 5
86
Garner R.A (2006) Managing Automotive Businesses Illinois Press
Gilbert D.R. (2009) Management 6th Edition London Butterworth

Stoner J.A.F. &
Freeman R.E
Batty J (2015) Industrial Administration New York McDonald and Evans
Markel M (2015) Technical New York Buffallo
Commmunication
Tebeauk E 2015 Essentials of Oxford Pearson
Technical
Communication
87
MINISTRY OF HIGHER AND TERTIARY EDUCATION,
INNOVATION, SCIENCE AND TECHNOLOGY
DEVELOPMENT
HIGHER EDUCATION EXAMINATION COUNCIL

(HEXCO)
OCCUPATIONAL STANDARD
FOR
DIESEL PLANT FITTING ARTISAN
88
SECTOR: AUTOMOTIVE ENGINEERING
QUALIFICATION FOR A DIESEL PLANT FITTING ARTISAN
QUALIFICATION CODE:
LEVEL: NATIONAL CERTIFICATE
DATE OF PROMULGATION:
89
Foreword
This document constitutes the first draft of a standard for the occupation of a Diesel Plant Fitting
Artisan which was developed using Occupational Competence Profiles (OCPs) as a basis.
This is in preparation for the registration of the Standards on the Zimbabwe Qualifications
Framework (ZQF). The ZQF is expected to be administered by the Zimbabwe Examinations and
Qualifications Authority (ZIMEQA) once the ZIMQA Bill currently before parliament becomes
law.
In line with the SADC Protocol on Education and Training, each SADC member state was
tasked to come up with its own Qualifications Framework that shall subsequently be linked to
the Regional Qualifications Framework (RQF). The development and registration of standards
on a qualifications framework is meant to facilitate the upward and horizontal movement of
individuals in their occupations, across occupations or in their areas of study – within the country
or the SADC region.
As a draft, certain sections have not yet been addressed. These sections are denoted by a [TBA]
and will be attended to as information is finalised.
For ease of reference, a definition of terms commonly used in this document is included in the
document.
This particular standard, for the occupation of a Diesel Plant Fitting Artisan, was developed with
the active participation of expert workers from the industry.
90
TABLE OF CONTENTS
Page
Foreword 2
Definition of Terms 4
Level Descriptors 6
List of Units and their Credit Values 7
Summary of Standard 8
Unit Standard 1 9
Unit Standard 2 13
Unit Standard 3 16
Unit Standard 4 18
Unit standard 5 22
Unit standard 6 25
Unit standard 7 28
Unit standard 8 31
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Definition of Terms
Assessment A process of collecting evidence of a learner’s work to measure and make

judgements about the achievement or non-achievement of the specified
National Qualifications Framework standards or qualifications.
Certification Awarding of approved documentary evidence of a qualification.
Common essential Universal skills which apply to more than one occupation.
skills
Competences Critical relevant knowledge, skills and attitudes a learner requires in order
required in to achieve specified outcomes before assessment.
readiness for
assessment
Credit The value assigned to a unit completed or a value assigned to a unit

standard which reflects the relative time and effort required to complete
the outcomes.
Date of Date when standard and qualification have been approved registered and
promulgation gazetted.
Element The smallest component of a unit with a meaningful outcome.
Level Position of achievement on the ZQF indicating depth, breadth and

complexity of competency.
Level descriptor A specific indicator of competence level on the ZQF.
Occupation A group of related economically beneficial work activities performed by a

person.
Performance A statement of competence or achievement against which the attainment

criteria of outcomes is measured.
Qualification Formal award of recognition of the achievement of the required

competency and/or capability level of the Zimbabwe Qualifications
Framework as may be determined by the relevant bodies registered for
such purpose by the Authority.
Range statement The context within which a competence is performed and assessed.
Review Date Date of revision of qualification as and when necessary but not later than
three years from date of issue.
92
Sector A section of the economy in which operators produce or provide similar
products or services.
Standard Registered statement of desired education and training outcomes and their
assessment criteria.
Unit The smallest combination of work activities capable of being a full-time

economically beneficial occupation.
Unit Standard Registered statement(s) of desired education and training outcomes, their
associated assessment criteria together with administrative information as
specified.
ZQF National qualifications framework approved by the minister for

registration of national standards and qualifications.
93
LEVEL DESCRIPTORS
[TBA]
(Information on the description of levels still pending)
94
UNIT TITLES
NO. UNIT CREDITS
1 Safe Working Environment Maintenance 30
2 Plant Maintenance 40
3 Engine Maintenance 30
4 Power Train maintenance 30
5 Hydraulic Systems Maintenance 20
6 Undercarriage Maintenance 10
7 Ground Engaging Tools Maintenance 20
8 Braking System Maintenance 20
9 Electrical and electronic system maintenance 20
95
SUMMARY OF STANDARD
UNIT UNIT TITLE CREDITS ELEMENTS

NO.
1 Safe Working 30 1.1 Practice and Adhere to Safety, Health
Environment and Environment
Maintenance
1.2 Use Appropriate PPE/PPC
1.3 Carry out risk assessment
1.4 Participate in safety Awareness
Meetings
2 Plant Maintenance 40 2.1 Prepare Maintenance Schedule
2.2 Conduct Visual inspection
2.3 Service/Repair plant
2.4 Test run plant
3 Engine Maintenance 30 3.1 Prepare service Schedule
3.2 Carryout trouble shooting
3.3 Service/ Repair engine
3.4 Test run the engine
4 Power Train 30 4.1 Prepare service schedule
maintenance 4.2 Carry out trouble shooting
4.3 Service/Repair Components
4.4 Test run for functionality
5 Hydraulic Systems 20 5.1 Prepare service schedule
Maintenance 5.2 Carry out trouble shooting
5.3 Service the units
5.4 Test run the system
6 Undercarriage 10 6.1 Prepare service schedule
Maintenance 6.2 Inspect the components
7 Ground Engaging 20 7.1 Prepare service schedule
Tools Maintenance 7.2 Inspect the components
8 Braking System 20 8.1 Prepare service schedule
Maintenance 8.2 Carry out trouble shooting
8.4 Test run for functionality
96
UNIT UNIT TITLE CREDITS ELEMENTS
NO.
9 Electrical and 20 9.1 Inspect electrical and electronic components
electronic system and circuits
maintenance
9.2 Dismantle starter motor
9.3 Inspect components
9.4 Reassemble components
9.5 Dismantle alternator
9.6 Inspect alternator components
9.7 Reassemble alternator
9.8 Perform electrical/electronic tests
9.9 Repair electrical circuits and components
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UNIT 1
Unit Title: SAFE WORKING ENVIRONMENT MAINTENANCE
Level of Unit: NATIONAL CERTIFICATE
Credits: 30
Occupation: DIESEL PLANT FITTING ARTISAN
Date of Promulgation: TBA
Review Date: TBA
AIM
This unit will enable an individual to assemble plant components to specified standards
ELEMENT AND PERFORMANCE CRITERIA
Element 1.1 Practice and Adhere to Safety, Health and

Environment
Performance Criteria:
1.1.1 Employees are introduced to safety, Health and Environment policies

1.1.2 Safety colour codes are established
1.1.3 Gangways are labelled
1.1.4 Storage areas are identified
1.1.5 Fire-fighting procedures are demonstrated
1.1.6 Tools and lifting equipment usage demonstrated
1.1.7 Handling of Hazardous substances manual produced
Element 1.2 Use Appropriate PPE and PPC
1.2.1 Personnel Protective equipment is used
1.2.2 Personnel Protective clothing is worn
1.2.3 Use of PPE and PPC is monitored
1.2.4 Organisational Standards and Regulations are enforced
98
Element 1.3 Carry out Risk Assessment
1.3.1 Housekeeping issues addressed.
1.3.2 Correct work procedure is followed.
1.3.3 Equipment register is enforced
1.3.4 Equipment storage procedure is observed/followed
1.3.5 Lock out mechanism is in stored
1.3.6 Hazardous areas are barricaded
1.3.7 Hot jobs, working on heights are permitted
1.3.8 Incidents reports are generated
Element 1.4 Participate in Safety Awareness Meetings
1.4.1 Safety meetings attended to

1.4.2 Meeting pointer are implemented
1.4.3 Safety signs and symbols are identified
1.4.4 Fire-fighting drills are carried out
1.4.5 Fire-fighting equipment identified.
1.4.6 Smoking zones are designated
1.4 7 Incidents reports are generated
Competencies Required in Readiness for Assessment:
Ability to interpret Statutes, Regulations

Knowledge of Safety, Health and Environmental regulations
Knowledge of Fire-fighting equipment, fire drills and fire prevention
Knowledge of report writing Skills
GENERIC SKILLS
Communication
Drawing
Reading and writing
Computers
Estimations
Measurements
Organizing
Planning
Analytical
Numeracy
99
RANGE STATEMENT:
Tools and equipment
Artisan’s toolbox
Lux meter
Noise level meter
Hydrometer
pH meters
Gas analyser
Thermometer
Camera
Tape measure
Breathlyser
Materials
Stationery
PPE
Duration: 300 Hours
ASSESSMENT AND CERTIFICATION:
In order to gain credits for this unit standard, a candidate must be assessed and demonstrate
competency in all the elements and performance criteria of this unit standard.
Assessment will be conducted by accredited assessors. The results of the assessment will be
submitted to ZIMEQA. A candidate can apply to ZIMEQA for documentary evidence of their
achievements.
100
UNIT 2
Unit Title: PLANT MAINTENANCE
Credits: 40
Review Date: TBA
AIM
This unit will enable an individual to successfully carry out maintenance of

components/equipment as per schedule and to specified standards
Element 2.1 Prepare Maintenance Schedule
2.1.1 A servicing program based on the machine time/mileage and with service intervals is
prepared
2.1.2 Specific tasks for each service interval and time frame are defined
2.1.3 Service kits and tools for each service interval are identified/listed/sourced
2.1.4 Relevant equipment and human resources are identified
2.1.5 Service record book/checklist are analysed
Element 2.2 Conduct Visual Inspection
2.2.1 Whole plant/machine is inspected

2.2.2 Notable defects are identified
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2.2.3 Plant/machine is cleaned
2.2.4 Plant/machine components are opened
2.2.5 Mileage/time is noted
2.2.6 Noted defects are listed/compiled
Element 2.3 Service/Repair Plant
2.3.1 SHEQ is observed
2.3.2 Visual inspection report consulted
2.3.3 Operation manual and appropriate tools and equipment are gathered
2.3.4 Serviceable components are changed according to manufacturer’s manuals
2.3.5 Defective components are repaired/replaced
Element 2.4 Test run Plant/machine
2.4.1 Necessary checks are conducted/analysed

2.4.2 Appropriate instruments are connected
2.4.3 Plant/machine is started according the specifications
2.4.4 Operating specifications are compared against manufacturer’s specifications
2.4.5 Necessary adjustments are carried out
2.4.6 Plant/machine service/repair report is produced
Ability to interpret engineering drawings

Appreciation of Engineering Mathematics
Appreciation of Engineering Science
Knowledge of and ability to use measuring instruments
Good knowledge of standard mechanical engineering practices
Knowledge of workshop machinery and tools
Knowledge of materials
102
Trouble shooting
Knowledge of Safety, Health and Environment regulations
GENERIC SKILLS
Communication
Drawing
Reading and writing
Computers
Estimations
Measurements
Organizing
Planning
Analytical
Numeracy
RANGE STATEMENT:
Tools and equipment
Artisan’s toolbox
Dynamometer Repair manual
Jacks and axle stands work-bench
Heavy duty spanners, sockets, screw-drivers and hammers measuring instruments
Torque wrench Valve adjustment set
Oil ring remover Allen keys
Micrometer Trays
Oil drainer Scrappers, files, centre
punches, Stocks and dies, hacksaws,
chisels Ring squeezer/expander
Overhead crane and lifts Injector tester
Parts catalogue Standard tool box
Hydraulic press/ puller Dial indicator gauge
Fire extinguisher Steam cleaner
Materials
Duration: 400 Hours
103
achievements.
104
UNIT 3
Unit Title: ENGINE MAINTENANCE
Credits: 30
Review Date: TBA
AIM
This unit will enable an individual to troubleshoot and repair faults on diesel plant machines and
components.
Element 3.1 Prepare Service Schedule
prepared
Element 3.2 Carry out Troubleshooting
3.2.1 Necessary instruments are connected to determine nature of failure

3.2.2 Printed results are analysed
3.2.3 Nature of problem is determined
3.2.4 Course of action is outlined/described
105
Element 3.3 Service/Repair Engine
3.3.1 Necessary resource are gathered (tools, equipment, manuals, HR and materials)
3.3.2 Appropriate servicing/repairing procedure is followed
3.3.3 Necessary checks are carried out
3.3.4 Prestart procedure (eg priming bearings) are conducted
3.3.5 Necessary running instruments are connected
Element 3.4 Test run Plant/machine


Trouble shooting
GENERIC SKILLS
Communication
Drawing
Reading and writing
Computers
Estimations
Measurements
106
Organizing
Planning
Analytical
Numeracy
RANGE STATEMENT:
Tools and equipment
Artisan’s toolbox
Micrometer Trays
punches,
Stocks and dies, hacksaws, chisels Ring squeezer/expander
Materials
Duration: 300 Hours
achievements.
107
UNIT 4
Unit Title: POWER TRAIN MAINTENANCE
Credits: 30
Review Date: TBA
AIM
This unit will enable an individual to become a successful diesel plant fitter.
prepared

4.2.5 Magnetic screen is removed to inspect debris
4.2.6 Scientific wear analysis is conducted on the oil
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Element 4.3 Service/Repair Components
Element 4.4 Test for Functionality


Trouble shooting
Good knowledge of network management
Knowledge of machine operation
Knowledge of monitoring and evaluation
Research methods
Ability to train and develop team members
109
GENERIC SKILLS
Communication
Drawing
Reading and writing
Computers
Estimations
Measurements
Organizing
Planning
Analytical
Numeracy
RANGE STATEMENT:
Tools and equipment
Artisan’s toolbox
Micrometer Trays
Oil drainer Scrappers, files, centre punches,
Materials
Duration: 300 Hours
achievements.
110
UNIT 5
Unit Title: HYDRAULIC SYSTEM MAINTENANCE
Credits: 20
Review Date: TBA
AIM
This unit will enable an individual to effectively maintain a safe working environment.
prepared

111
Element 5.3 Service/Repair Units
5.1.1 Implement cycles are checked

5.1.2 Safety precautions are observed due to high pressure and raised implements
Element 5.4 Test run the System


Trouble shooting
Knowledge of report writing
Knowledge of memo and letter writing
Knowledge of minute writing
Knowledge of Record management
Knowledge of coordinating meetings
112
Knowledge of Public relations
GENERIC SKILLS
Communication
Drawing
Reading and writing
Computers
Estimations
Measurements
Organizing
Planning
Analytical
Numeracy
RANGE STATEMENT:
Tools and equipment
Artisan’s toolbox
Micrometer Trays
Materials
Duration: 200 Hours
achievements.
113
UNIT 6
Unit Title: UNDERCARRIGE MAINTENANCE
Credits: 10
Review Date: TBA
AIM
prepared
Element 6.2 Inspect the Components
6.2.1 Visual inspection is carried out

6.2.2 Specialised is applied and referred to specs and recommendations
6.2.3 Necessary course of action is determined
114
6.3.1 Necessary resources are mobilised

6.3.3 Test run is conducted
6.3.4 Necessary adjustments carried out

Knowledge of report writing

Knowledge of memo and letter writing
Knowledge of minute writing
Knowledge of Record management
Knowledge of coordinating meetings
Knowledge of Public relations
Trouble shooting
115
GENERIC SKILLS
Communication
Drawing
Reading and writing
Computers
Estimations
Measurements
Organizing
Planning
Analytical
Numeracy
RANGE STATEMENT:
Tools and equipment

Artisan’s toolbox
Micrometer Trays
punches,
Materials
Duration: 100 Hours
achievements.
116
UNIT 7
Unit Title: GROUND ENGAGING TOOLS MAINTENANCE
Credits: 20
Occupation: DIESEL PLANT FITTER
Review Date: TBA
AIM
prepared
Element 7.2 Inspect the Components

117

7.3.3 Worn out components are replaced
Hydraulics
Material science
Basic electrics
Care, use and storage of tools and equipment
GENERIC SKILLS
Communication
Drawing
Reading and writing
Computers
Estimations
Measurements
Organizing
Planning
Analytical
Numeracy
RANGE STATEMENT:
Tools and equipment
Artisan’s toolbox
Micrometer Trays
punches,
118
Materials
Duration: 200 Hours
achievements.
119
UNIT 8
Unit Title: BRAKING SYSTEM MAINTENANCE
Credits: 20
Review Date: TBA
AIM
prepared
Element 5.2 Conduct Visual Inspection

5.2.2 Tooling is applied and refer to specs and recommendations
5.2.3 Necessary course of action is determined
120
Element 5.3 Service/Repair Components

5.1.6 Prestart procedure (e.g. priming bearings) are conducted

Material science
Types of braking systems, operation; service and repair
Hydraulics
Types of brake fluids and oils -Use knowledge of Hydraulic and -Mechanical hand and foot
brakes
Functions of the braking systems:
Mechanical.
Hydraulic.
Pneumatic.
Operation of master cylinders:
121
GENERIC SKILLS
Communication
Drawing
Reading and writing
Computers
Estimations
Measurements
Organizing
Planning
Analytical
Numeracy
RANGE STATEMENT:
Tools and equipment
Artisan’s toolbox
122
Dynamometer
Repair manual
Work-bench
Heavy duty spanners, sockets, screw-drivers and hammers
Measuring instruments
Torque wrench
Allen keys
Micrometer
Trays
Injector tester
Parts catalogue
Standard tool box
Dial indicator gauge
Fire extinguisher
Steam cleaner
Materials
Duration: 200 Hours
achievements.
NATIONAL CERTIFICATE IN DIESEL PLANT FITTING – 319/21/CR/0
UNIT 9
Unit Title:9 ELECTRICAL AND ELECTRONIC SYSTEMS
Unit Code
ZQF Level: NATIONAL CERTIFICATE
Credits: 20
Date of Promulgation:
Review Date:
AIM
On completion of this unit the individual will be able to carry out checks and tests on electrical
and mechanical vehicle systems
ELEMENTS AND PERFORMANCE CRITERIA
Element 9.1 Inspect electrical and electronic systems
9.1.1 Suitable tools and equipment are selected

9.1.2 Safety precautions are followed
9.1.3 Starting and charging system is checked for functionality
9.1.4 Functionality of warning lights and gauges established
9.1.5 Wires and connections are checked for tightness and damages
9.1.6 Operation of all lights and accessories checked
9.1.7 Battery checks done
124
Element 9.2 Dismantle starter motor
9.2.1 External starter motor connections disconnected
9.2.2 Starter solenoid removed
9.2.3 Brush box housing removed
9.2.4 Brush holder removed
9.2.5 Field coil housing removed
9.2.6 Yoke is disconnected
9.2.7 Armature is removed
9.2.8 Overrunning clutch is removed
Element 9.3 Inspect components
9.3.1 Components are cleaned using appropriate solvent

9.3.2 Brushes are checked and inspected for wear
9.3.3 Armature inspected wear and insulation (ground)
9.3.4 Growler test is carried out on the commutator
9.3.5 Overrunning is inspected for slippage (one way clutch)
9.3.6 Bearings and bushes inspected for wear
9.3.7 Overrunning clutch housing is inspected for wear and cracks
9.3.8 Pinion is inspected for teeth chipping
9.3.9 Commutator inspected for insulation
9.3.10 Solenoid is tested for pull in and hold in
125
Element 9.4 Re-assemble starter motor
9.4.1 Overrunning clutch is assembled into the housing

9.4.2 Yoke is replaced
9.4.3 Commutator is connected to the yoke and the clutch
9.4.4 Armature is correctly installed
9.4.5 Field coil housing fitted correctly
9.4.6 Brush box is replaced onto the commutator
9.4.7 Positive brushes connected and fitted to the brush cage and insulated
9.4.8 Brush box is fitted onto the field coil housing
9.4.9 Solenoid and the external wire are connected back correctly
9.4.10 Starter motor is tested for motoring, cranking and hold-in
Element 9.5 Dismantle alternator
9.5.1 Remove the rear end cover

9.5.2 Remove the regulator
9.5.3 Remove front pulley using special service tool
9.5.4 Remove the front end cover
Element 9.6 Inspect components
9.6.1 Clean the components using appropriate solvent

9.6.2 I.C regulator diodes are checked for insulation
9.6.3 Brushes and bearings are checked for wear
9.6.4 Slip rings are checked for open C.C.T and wear and ovality
126
9.6.5 Rotor segments are checked for insulation

9.6.6 Stator is checked for grounding and continuity
9.6.7 Pulley is checked for chips and cracks
Element 9.7 Re-Assembling of Alternator
9.7.1 Pulley is fitted back to the front-end cover and rotor

9.7.2 Stator is fitted and correct bearing is replaced
9.7.3 Bearing is greased using appropriate lubricants
9.7.4 I.C regulator is replaced onto the rotor
9.7.5 Rear end cover is replaced
9.7.6 Alternator is tested for charging
Element 9.8 Perform electrical tests
9.8.1 Suitable tools and equipment selected

9.8.2 Safety precautions followed
9.8.3 Bearing is greased using appropriate lubricants
9.8.4 I.C regulator is replaced onto the rotor
9.8.5 Rear end cover is replaced
9.8.6 Alternator is tested for charging
Element 9.9 Perform electrical tests on circuits and components

9.9.3 Circuits checked for continuity
9.9.4 Voltage drop/output is tested
9.9.5 Current draw tested and results compared with specifications
9.9.6 Resistance is measured against specifications
9.9.7 Battery tests done to ascertain condition
9.9.8 Operation of air conditioning system is checked
127
Element 9.10 Repair electrical circuits and components

9.10.3 Faulty components identified
9.10.4 Faulty components removed as per repair manual
9.10.5 Components repaired/replaced and fitted back
9.10.6 Faulty circuits rectified and tested for functionality
9.10.7 Battery tests done to ascertain condition
9.10.8 Terminals and connections cleaned and lubricated
COMPETENCIES REQUIRED IN READINESS FOR ASSESSMENT

Electrical fault finding
Electrics and electronics problem solving
Automobile electrical principles
Automobile electronic principles
Workshop safety
COMMON ESSENTIAL SKILLS:

Computer literacy
Communication
Supervision
Vehicle driving
RANGE STATEMENT:
Tools and equipment
Diagnostic machine
Vernier callipers
Standard tool box
Digital Multimeter
Battery load tester and charger
Workbench with bench vice
Personal protective equipment
Puller
Copper jaws
Soldering iron
Growler
Hydrometer
Test meter
128
Beam setter
Materials
Cleaning agents
Mutton cloth
Protective clothing
Water paper
Fuses
Degreaser
Insulation tape
Soldering wire
Grease
DURATION 200 Hours
achievements.
129
NATIONAL CERTIFICATE IN DIESEL PLANT FITTING 2018
MINISTRY OF HIGHER AND TERTIARY EDUCATION, CODE

DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE
INDUSTRY TRADE/ OCCUPATION CLASS/ LEVEL
AUTOMOTIVE DIESEL PLANT FITTING NC
DUTY A: SAFTEY, HEALTH, ENVIROMENT, AND QUALITY MAINTAINANCE
Pre-requisites: Approval Date: Review Date:
TASK STEPS PROFICIENCY INDICATORS RELATED WORKPLACE
KNOWLEDGE ESSENTIAL SKILLS
A1: Observe personal  Carry out risk assessment  Risk assessment report  Factories Act and o Communication
safety and health produced Regulations
 Put on appropriate personal o Coordination
protective gear.  Warning signs observed  SHEQ standards
o Firefighting Equipment
 Interpret safety warning signs  Personal protective gear  First Aid handling
worn.
 Use safety regulation rules  Fire Fighting
 Correct tool used for job
 Use correct tool for the right job and properly handled  Computer Literacy
 Handle tools and equipment  Accident register

appropriately maintained.
 Maintain accident report register
A2: Demonstrate first  Ensure personal safety.  Personal safety ensured.
130
Aid procedure  Call for nearby assistance.  Victim removed from

danger
 Remove victim from danger
following laid down procedure.  Assistance from nearby
obtained.
 Introduce yourself to the victim.
 Appropriate first aid
 State your intention to the victim rendered.
 Assess victim condition
 Communicate with victim (where

necessary)
 Render appropriate first aid action

as required
 Call for medical assistance
 Document incident
A3: Maintain safe  Put on appropriate PPE.  Appropriate PPE

working conditions worn
 Barricade the working area.
 Barricades installed
 Practice safe working
environment  Safety precautions
observed.
 Place tools and equipment in
appropriate positions.  Tools and equipment
well placed.
 Tidy up the places as per
procedure  Appropriate tools
used for right job.
131
 Segregate the waste  Tolls and equipment

checklist availed
 Dispose waste following laid
down procedure  Waste management
disposal procedures
 Store tools and equipment as observed.
per standard.
A4: Perform  Clean working area  Clean working area

Housekeeping
 Clear gang ways of obstacles  Gang ways free of
obstacles
 Separate waste materials to c lass
 Classified waste materials
 Sweep floors regularly
 Clean floors
 Clean tools and equipment after
use  Clean stored tools and
equipment
 Store tools and equipment
according to rules and regulations
A5: Comply with  Identify potential environmental  List/ register of potential

environmental aspects environmental aspects
management systems
 Adhere to relevant statutory  Spillage free
instruments environment
 Dispose waste in line with local  Lower waste material

authority regulations
 Clean environment
 Prevent unnecessary spillages to
the environment  Colour coded bins
132
 Implement Reduce recycle and

reuse practices
A6: Participate in  Mobilise SHEQ awareness  SHEQ campaign materials

SHEQ awareness campaigning material availed
campaign
 Attend SHEQ briefing meeting  Attendance
register/Minutes
 Identify potential hazards
 Hazards Register
 Induct new personnel on SHEQ
issues  Loss incidences
 Adhere to SHEQ rules and  Proper Personal

regulations Protection Equipment
(PPE)
 Enforce SHEQ rules and regulations
A7: Maintain  Identify relevant quality standards  List/register of relevant

organizational quality standards
standards  Perform quality checks produced
 Adhere to standard operating  Quality checks conducted
procedures in accordance to set
 Maintain product quality procedures
 Operational checklist
 Quality products
133
TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

First aid kit.
Safety signs and symbols.
Awareness campaigns material.
HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

Personal protective gear
Use of proper insulated tools
Use of calibrated instruments incompliance to ISO standards
Free gang ways at the worksite
Floors free of slippery conditions
Safety insignia post at all relevant areas.
SPECIFIC WORKER TRAITS REQUIRED COMPLETING THIS DUTY:

Team work
Sober minded
Communication
Honest
Punctual
Target orientated.
134

DEVELOPMENT
INDUSTRY: TRADE/OCCUPATION: CLASS/LEVEL:
DUTY A: OVERHAUL POWER-TRAIN SYSTEM
TASK STEPS PROFICIENCY INDICATORS RELATED KNOWLEDGE WORKPLACE
ESSENTIAL SKILLS
A1: Replace clutch  Select suitable tools  Suitable tools and equipment  Clutch function o Communication
assembly selected
 Disconnect battery/switch off master  Principles of operation o Drawing
key  Fenders covered o Reading and
 Identification of
 Choke wheels writing
 Battery earth terminal components
o Computers
 Drain transmission/gear box oil disconnected
 Types of clutches
o Estimations
 Tag and lock out  All electrical connectors are
 Friction clutches o Measuring
 Removal disconnected and re-connected
according to manual  Centrifugally assisted o Organizing
 Disconnect propeller shaft from
gearbox output shaft flange specifications clutches o Planning
 Remove starter motor  One side of live axle is jacked up  Fault diagnosis and o Analytical
135
 Remove slave cylinder/ clutch  Gearbox is drained in analysis and o Numeracy

linkages containers rectification
 Remove bell housing bolts /nuts  Push-rod adjusted to  Testing techniques of

 Disconnect speedometer cable specifications components
 Disconnect electrical connections  Work done within stipulated  Knowledge on
 Remove gearbox housing bolts time Technical drawing
 Withdraw gearbox  Dismantling of components  Tools and equipment

done according to set
 Remove thrust bearing, fork pressure
and clutch plates and flywheel procedures
 Reassembling  Flywheel is de-glazed and

checked
 Replace defective components
 Fit new pressure plate and clutch  Visual inspection of pressure

plate and clutch plates, flywheel,
thrust and pilot bearings,
 Fit new thrust bearing and clutch fork
gearbox mounting and clutch
 Fit gearbox fork
 Fit gearbox mounting bolts
 Bolts tightened to
 Tighten gearbox mounting bolts manufacturer’s specifications
 Fit cross member using torque
136
 Fit propeller shaft  Wrench
 Connect gearbox and clutch linkages  Gearbox supported and not

 Connect propeller shaft left to hang
 Grease universal joints
 Connect all accessories
 Fit starter motor
 Fit slave cylinder
 Lower vehicle
 Fill up gearbox with oil
 Remove tag and lock
 Connect gear lever/shift
 Connect battery/switch on master

key
 Bleed and adjust clutch
 Start vehicle
 Check operation
 Test
137
A2: Remove  Select suitable tools and equipment  Correct use of tools and
torque equipment
converter/divider  Clean work area
 Disconnect battery  Correct handling of tools and

equipment
 Choke wheels and Jack machine and
support on stands  Use of trays
 Drain oil  Locating drive/ flexi-plate

 Remove covers/ belly plates and converter bolts done
disconnect pipes
 Battery earth removed first
 Put lifting tackle into position
 Correct positioning of lifting
 Remove charge pumps, hydraulic
equipment
pump propeller shaft, planet gear
train and inspection plate
 Decouple drive plate from flywheel
 Loosen and remove torque

converter/divider
A3: Overhaul  Clean torque converter  Seating pattern and bearing

torque converter/ clearance in housing observed
divider  Clean work area
with special attention on
 Separate impeller and carrier from wobbling of shaft
housing
 Correct assembling order
138
 Remove impeller, stator followed and turbine splines

unidirectional clutch and turbine checked against shaft splines
 Remove bearings from housing  One-way shaft fitted correctly

 Clean components
 Impeller to stator clearance
 Visually inspect impeller, turbine checked using plastic gauge in
stator, and housing, input and output conjunction with micrometer as
shaft
opposed to checking turning
 Replace defective components resistance
 Dismantle converter inlet and outlet  Turbine to stator clearance,

valves and clean
properly checked as above
 Re-assemble torque converter
 Turbine impeller, vanes and fins
 Clean torque converter counted against specifications
 Fit torque converter housing bearings
 End float checked for stator
 Fit turbine, one-way clutch stator, adjusting as necessary
impeller into housing
 Unit in assembled mode
 Check clearances
checked for smooth turning
 Block all ports and clean cylinder
 All seals replaced
 Remove end caps
 Planetary gears backlash
 Remove spring retaining clips
139
 Withdraw spool from valve block checked
 Remove seals from block  Output shaft pre-loaded

 Remove pressure relieve valve
 Needle bearings –planetary pin
 Clean and inspect components clearance hand checked
 Turning resistance checked
 Fit seals and fit spool into valve block
 Output shaft flange seal area
 Fit springs, circlips, end caps and
checked for grooving and seal
o pressure relief valve changed
 Test inlet/outlet valve

 Output shaft pre-load checked
 Fit seal ring from converter to divider
 Turning resistance checked
 Fit planetary gear train
 Fit seals correctly
 Fit housing cover
A4: Remove  Select suitable tools and equipment  Correct use of tools and
automatic/ semi- equipment
automatic  Clean work area
transmission  Safety precautions adhered to
 Disconnect battery
 Disconnect propeller shaft  Correct plugs/caps used to plug

ports
 Remove mounting bolts to rear axle /
final drive  Correct positioning of lifting
140
 Disconnect linkages and hydraulic equipment observed

pipes from pumps, body and filters
 Plug /cap open pipes/ports
 Put lifting equipment in position
 Lift out unit
A5: Overhaul  Select suitable tools  Correct use of tools and

transmission equipment
 Clean transmission
 Remove output flange  Safety precautions adhered to
 Take off transmission housing bolts  Correct disassembling

and remove transmission valve group procedure followed
 Remove clutch pack and dismantle  Inspect separator plates and

clutch pack
friction discs for wear
 Remove all seals and bearings
 Ring gaps checked for metal
 Take out separator plates and friction rings
discs
 Housing checked for wear
 Remove piston from housing
 Remove all shafts  Friction and separator plate

thicknesses measured against
 Clean and visually inspect
specifications
components for wear and damage
141
 Assemble transmission  Clutches end play measured
 Replace piston seals and fit piston  Shaft wear checked (seal ring
into clutch housing areas)
 Replace all seals and bearings
 Seals and bearings fitted
 Fit friction and separator plates into correctly
clutch housing
 Fit pressure plates and retaining

circlips
 Fit all shafts back
 Test clutch plate engagement using

air pressure
 test transmission unit and adjust
A6: Replace clutch  Select suitable tools  Suitable tools and equipment
booster/air pack selected
 Choke wheels
 Disconnect air pipes and hydraulic  Fenders covered

pipes
 Battery earth terminal
 Remove clutch air pack mounting disconnected
bolts/booster
 Work done chronologically
 Withdraw clutch air pack /booster
 Work done within stipulated
142
 Fit new clutch air pack/booster time
 Fit cross member  Work done within stipulated
 Fit propeller shaft time
 Connect air pipes and hydraulic pipes  Bolts tightened to

manufacturer’s specifications
 Start vehicle
using torque
 Check operation
 Road test
A7: Repair clutch  Select suitable tools  Suitable tools and equipment
master selected
cylinder/slave  Cover fenders
cylinder  Fenders covered
 Choke wheels
 Disconnect fluid pipes disconnected
 Remove clutch master cylinder  Work done chronologically

mounting bolts
 Disconnect pushrod from clutch time
pedal
 Withdraw clutch master cylinder
time
 Remove reservoir
 Remove pushrod from clutch master
143
cylinder using torque Wrench
 Remove clutch slaver cylinder
 Disconnect pushrod from fork
 Remove piston seals and springs
 Clean and inspect components
 Fit new components
 Connect pushrod to clutch pedal
 Mount clutch master cylinder/slave

cylinder
 Connect fluid pipes
 Fill up reservoir
 Bleed and adjust clutch system
 Start vehicle
 Check operation
 Road test
A8: Replace clutch  Select suitable tools  Suitable tools and equipment
cable selected
144
 Cover fenders  Fenders covered
 Choke wheels  Battery earth terminal

disconnected
 Disconnect cable from clutch fork
 Disconnect cable from bell housing time
bracket
 Disconnect cable from clutch pedal manufacturer’s specifications
using torque Wrench
 Remove rubber glommet
 Withdraw cable
 Connect new clutch cable to clutch

pedal
 Connect new clutch cable to fork.
 Tighten new clutch cable mounting

brackets
 Check operation
 Adjust new cable
 Road test
145
A9: Replace  Select suitable tools  Correct use of tools and

propeller shaft equipment
/universal  Disconnect battery/switch off master
joints/Centre key  Battery earth terminal
bearing disconnected
 Clean work area
 Choke wheels
 Tag and lock out time
 Raise one side of live axle  Use of recommended cleaning

solvents
 Drain gearbox oil
 Correct alignment of propeller
 Indent match marks on flanges shaft
 Disconnect propeller shaft from  Match marks on flanges aligned

pinion and gearbox output shaft on assembling
flange  Correct replacement parts
fitted
 Remove centre bearing mounting
bolts and bearing  Bolts tightened to
 Withdraw propeller shaft assembly using torque Wrench
 Remove retaining circlips  Propeller shaft splines checked
for wear
 Remove universal joints (UJs)
 Recommended grease used to
 Remove spiders
grease shaft
146
 Inspect all components
 Replace all worn and defective

components
 Replace universal joints and retaining

circlips
 Fit greasing nipples and grease shaft
 Slide propeller shaft assembly into

gearbox and align to pinion flange
 Mount propeller shaft mounting bolts

and nuts to final drive flange
 Secure centre bearing
 Fill gearbox oil
 Lower vehicle
 Connect batteries
 Remove tag and lock equipment
 Test run machine
A10: Overhaul  Select suitable tools and equipment

differential unit  Correct use of tools and  Tools and equipment
 Clean work area equipment use and handling
 Work hazards related
147
 Choke wheels  Battery earth terminal to this duty
disconnected
 Disconnect battery /switch off master  Identification of
key components and their
 Safety precautions adhered to material science
 Disconnect shaft from propeller
flange  Proper wheel chokes used  Operation and purpose
of differential unit
 Remove axle shaft splined to sun  Seal installed facing correct side
gears  Fault diagnosis i.e
defects, causes and
 Tooth contact pattern
 Remove differential assembly from rectification
banjo housing measured and adjusted to
specifications  Measurements to be
 Punch mark bearing caps on carried out on
differential cage  Backlash is checked and differential unit and
procedures
 Remove bearing caps adjusted
 Adjustments procedure
 Secure shims to corresponding caps  Pinion gear depth is measured
 Dismantling and
 Remove differential cage, planet and adjusted
assembling procedures
gears
 Bearing pre-load is measured  Inspection of
 Remove pinion flange nut and flange, and adjusted according to components
sun gears and washer
 Remove pinion from housing
 Centre bearing replaced
 Clean and inspect all components
 Shim with chamfer facing gear
 Replace all defective components
148
 Fit bearing on pinion shaft side is fitted
 Install outer bearing race  Bearings fitted correctly onto
 Install pinion into case /housing pinion using hot oil bath or
shaft shrunk using liquid
 Pre-load pinion bearing
nitrogen
 Lock pinion nut
 Oil coolant levels checked
 Install sun gears and planet gears
 Install bearings on differential cage  Engineers blue used to check

into housing tooth contact pattern
 Fit caps to mating surface and pre-  Gears visually inspected for
load
wear and chipping
 Check backlash and tooth contact
pattern
 Fit differential assembly to banjo

housing
 Fit axle shafts and road wheels
 Connect propeller shaft to pinion

flange
 Fill differential with oil
 Connect batteries/switch on master
149
key
 Remove wheel chokes
 Test machine
A11: Overhaul/  Select appropriate tools and

replace electric  A list of appropriate selected
equipment
solenoids tools and equipment
 Disconnect solenoid connections
 Disconnected solenoids
 Remove solenoid
 Test solenoid for functionality  New functional solenoids
 Replace solenoid seals  Cleaned valve body
 Inspect return spring, wiring and

plunger/solenoid
 Clean the valve body and connection
A12: Overhaul  Select appropriate tools and

valve body  A list of appropriate selected
equipment
tools and equipment
 Disconnect battery/ switch off master
key  Disconnected battery
 Remove Valve body

 Clean valve body
 Clean valve body
 Functional valve body
150
 Strip valve body
 Check spools and valves
 Replace seals
 Inspect housing for damage
 Clean all components
 Assemble valve body
 Fit/Mount valve body
 Reconnect all necessary components
 Test run valve body and make

necessary adjustments
A13: Service or  Select appropriate tools and 

replace filtration  A list of appropriate selected
equipment
system tools and equipment
 Disconnect battery/ switch off master
key  Disconnected battery
 Choke wheels
 Drained oil
 Tag and lockout
 New service components
 Remove filters
 Drain oil
151
 Sent sample oil for analysis
 Remove and clean the screen
 Remove sump (where necessary)
 Cut and inspect the filter in half and

inspect
 Inspect oil cooler
 Replace and reassemble necessary

components
 Recharge transmission oil
A14: Verify  Select appropriate tools and

Transmission  A list of appropriate selected
equipment
pressures tools and equipment
 Clean the whole machine
 A completed checklist
 Connect gauges before running the
machine
 Start and note the measurements/

readings (Cold)
 Run machine to operating

temperature
 Take note the measurements/

readings (Hot/ Maximum operating
152
temperature)
 Analyze measurements / readings

according to specifications

Micrometer Trays
Utilize Personal protective clothing (PPE)

Workplace safety rules
Environmental protection agency regulations and occupational safety and health administration
Proper use of tools
First aid
Understand common safety hazards in automotive repair business
Hazardous material and waste control
Types of fires, fire extinguishers and operating procedures
153
SPECIFIC WORKER TRAITS REQUIRED TO COMPLETE THIS DUTY:
Honesty Punctual Team worker Physically fit Sober minded

Dedicated Competent Tolerant Focused
154

DEVELOPMENT
DUTY B: OVERHAUL ENGINE
TASK STEPS PROFICIENCY INDICATORS RELATED KNOWLEDGE WORKPLACE ESSENTIAL
SKILLS
B1: Remove engine  Select suitable tools -Correct use of tools and equipment  -Tools and equipment o Communication
 -Battery earth terminal handling and use
 Choke wheels disconnected o Drawing
 -Repair standards
 Disconnect battery  -All electrical connectors are o Reading and
safely disconnected  Use of repair manuals writing
 Remove covers
 -Work done within stipulated  -Occupational health o Computers
 Drain engine oil time
and safety precautions
o Estimations
 Drain coolant  -Engine oil and water drained in  -Simple dis-assembly of
engines o Measurements
containers
 Remove radiator hoses
 -Specification, types and o Organizing
155
 Remove radiator  -All pipes to be blocked principles of engines o Planning
 Disconnect all electrical  -Lifting position identified as  -Removal and o Analytical

connections stated in service manual installation of engines
o Numeracy
 Remove starter motor  -Engine removed within  -Types of engines and
manufacturer’s time their operation-4 stroke,
 Remove hydraulic pipes specifications 2 stroke etc
 Remove pneumatic pipes  -Engine components and

their functions
 Disconnect all accessories
 -Tools and equipment
 Put lifting tackle in position and correct usage
 Connect hoist  -Engine faults, causes

and rectification
 Remove engine mounting bolts
 -Cooling system and
 Detach engine from other components
components
 -Fuel and lubrication
 Lift engine out systems and
components
 Place engine on work-bench or
stands  -Air induction systems
for naturally aspirated
B2: Dismantle engine  Select suitable tools  -Correct use of tools and and turbo charged
equipment engines
 Clean engine
 -Correct cleaning solvents used  -Turbo chargers and air
 Remove clutch assembly/torque
cleaners
converter, flywheel and housing  -Provide for workplace
156
 Remove hydraulic pumps and cleanliness and orderliness  -Engine related non-
compressor and water pump electric circuits like oil
 -Ports blocked before engine is
coolers and after coolers
 Remove the following: cleaned and related components
- tappet cover  -Engine disassembled following  -Measuring, adjustment,
manufacturer’s specifications component and parts
- cylinder head
 -Visual inspection carried out on replacement
- oil and fuel filters all components  -Testing of cooling
- high pressure pipes  -Correct loosening sequence systems, governors, fuel
and injector pump followed in dismantling following systems, lubrication
components: rocker shaft, systems
- rocker shaft assembly
cylinder head and crankshaft  -Air induction, turbo
and push-rods
 -Big end bearing caps marked in chargers, air cleaners,
- timing cover coolers and hydraulic
relation to camshaft
systems
- timing gear train
 -Piston marked in relation to
 -Dynamometer testing
- sump connecting rod
of engines
- oil strainer and pump  -Main bearing cap marks
indented to position on cylinder
- crankshaft balance block
weights
 -Crankshaft positioning observed
 Clean and dry all components
 Visually inspect all components
B3: Inspect engine  Select suitable tools  -Correct use of tools and
equipment
157
components  Clean engine  -Correct cleaning solvents used
 Provide for workplace orderliness  -Clean and orderly workplace
and cleanliness  Crankshaft measured for – taper,

ovality, run out and size
 Visually inspect components
 Visual inspection of all
 Measure crankshaft journals components for physical wear
and distortion as follows:
 Inspect connecting rod
 Piston, Cam lobes, Cam
followers,
 Measure cylinder block
 Push rods, Rocker shaft, arm
 Inspect and measure piston, bushes and heel, timing gears
and bushes Crankshaft balancer,
 camshaft, cam followers, push
 -Oil pump housing, rotor, vane.
rods and rocker shaft assembly
 -Water jackets and oil galleries
 Inspect gear train, crankshaft
balance, oil pump, water pump  for blockage, cracks and
corrosion
 Replace seals  -Cylinder block measured for
straightness
 Measure cylinder block
 -Damaged or loose core plugs
 Check core plugs replaced
 -Piston skirt measured for ovality

 Check piston, connecting rods,
and wear in relation to cylinder
158
crankshaft, camshaft and oil bore
pump  -Piston ring groove clearance

measured against
manufacturer’s specification
 -Gudgeon pin piston clearance

measured
 -Clearance between housing and

rotor /gear measured against
 -Clearance between rotor and

vane measured against
 -Clearance between driving and

driven gear measured against
 -Oil pump bushes to shaft

clearances measured against
specifications
 -Condition of relief valve

checked
B4: Overhaul cylinder  Select suitable tools  Correct use of tools and
head equipment
 Provide for workplace cleanliness
and orderliness  Recommended cleaning solvents
159
 Clean cylinder head used
 Remove thermostat housing  Provide for workplace

cleanliness and orderliness
 Remove injectors
 Valves marked at the centre of
 Mark valves valve head in numerical
 Remove valve springs and valves sequence
 Measure cylinder head thickness  Valve guide stem clearance

measured
 Check cylinder head warpage
 Valve collets checked for wear
 Test for cracks cylinder head and replaced where necessary
 Remove valve guides and valve  Valve springs measured for

seat tension according to
 Repair/replace defective valve
guides and valves  Valves checked for straightness,
stem wear and land thickness
 Cut valve seats
 Cylinder head thickness and
 Cut valve angle
warpage measured according to
 Lap valves, clean and assemble manual
 Carry out valve leakage test  Valve angles cut according to

manual
 Valve springs fitted correctly
B5: Assemble engine  Select suitable tools  Timing marks noted on injector
160
 Clean and dry engine block pump, crankshaft balancer and

gear train
 Provide for workplace cleanliness
and orderliness  Oil pump gasket /seal changed
 Fit new main bearings on block  New sump gasket fitted

and caps and thrust washer
 Correct side noted
 Lay crankshaft into block
 Water jackets, oil galleries to
 Fit main bearing caps and align with gasket
connecting rod to piston
 Tightening sequence followed as
 Fit piston rings per service manual
 Fit big end bearings, piston and  Bolt threads lubricated as per
connecting rod assembly to manual instruction
crankshaft
 Fit cam bushes, camshaft, cam manufacturer’s specification
followers and gear train following
 Fit lift pump, injector pump,  correct sequence

injectors and high-pressure pipes,
back plate crankshaft balancer, oil  Rocker arms adjusting screws
loosened to Suitable tools and
pump, strainer, sump
equipment used
 Carry out valve timing
 Cylinder liners pressed out
 Fit idler gears, timing cover seal,
timing cover and injector pump  Liner bore diameter and
protrusion checked against
high pressure pipes
manual specifications
161
 Place cylinder head gasket  Safety precautions observed
 Fit cylinder head, push rods and  Position of oil galleries and lugs
rocker shaft assembly observed
 Adjust valve clearances  Crankshaft end-float measured

i.e correct size thrust washer
 Fit tappet cover, crankshaft fitted
pulley, thermostat housing, water
pump  Correct size main bearings fitted
 Fit oil and fuel filters  Thrust size noted when fitting
pistons to connecting rod
 Fill engine with oil
 Bearing nip/crush checked
 Mount engine on dynamometer
 Oil clearances checked
 Fit starter motor and alternator
 Piston rings position noted
 Connect water hoses
 Piston ring clearances and
 Connect all electrical connectors working gaps measured against
 Start engine specifications
 Check oil pressure  Piston rings staggered
 Check oil leaks and water leaks  Bearing crush /nip checked
 Load engine  Oil clearances measured on big

end bearings
 Check load appreciation
 Position of cam bushes holes in
 Run in engine relation to oil galleries noted
162
 Re-torque engine  prevent bending of push rods
 Remove engine from  Valve clearance adjusting

dynamometer sequence observed and adjusted
according to manual
specifications
 New rocker cover gasket fitted

and tightening sequence
observed
 Thermostat housing and cylinder

head surfaces are cleaned
 New thermostat housing gasket

fitted
 New water pump gasket fitted
 Fuel filter filled with fuel
 Oil and fuel filter seals lubricated
 Bolts tightened to specified

torque.
 Injectors checked for correct

spray pattern
 Injector pump timed
163
6: Overhaul water  Select suitable tools  Suitable tools and equipment

pump selected
 Clean work area
 Working area clean and free of
 Remove drive pulley, flange,
dust
bearing securing circlip and
impeller cover  Recommended cleaning solvent
used
 Press out spindle shaft, spindle
and bearings from impeller side  All bolts tightened to specified
torque
 Clean and inspect housing,
spindle and bearings  Seal fitted without damage and
facing correct side
 Replace seal
 Running surfaces of impeller and
 Replace bearing and retaining mechanical seal in contact
circlip
 Impeller clearances measured
 Fit impeller and cover against specifications
 Fit flange and drive pulley
 Test water pump for functionality
B7: Overhaul turbo  Select tools and equipment  Suitable tools and equipment
charger selected
 Remove turbine and impeller
 All bolts tightened to specified
 Remove shaft retaining circlip torque
 Press out shaft from cartridge  Safety precautions observed
 Remove seals and bearings  Shaft checked for straightness
164
 Clean and inspect components  Housings checked for wear and

damage
 Fit bearings
 Impeller and turbine clearance
 Press in shaft measured against specifications
 Fit seals and shaft retaining circlip
 Fit impeller and turbine
 Fit impeller and turbine housing
 Test for smooth running
B8: Overhaul injector  Select suitable tools  Correct use of tools and
pump equipment
 Provide workplace cleanliness and
orderliness  Recommended cleaning solvents
used
 Remove delivery valves and mark
 Provide for workplace
 Removing pumping elements,
cleanliness and orderliness
remove rack, pump camshaft and
governor assembly  Safety precautions adhered to
 Clean and inspect components  A mighty marker is used in

marking delivery valves and
 Replace defective components pumping elements
 Fit pump camshaft and rack  Delivery valve spring tension
 Place pumping elements checked against specifications
 Fit delivery valve and governor  Pumping elements and delivery

valves fitted to original position
165
assembly  Pump calibration and phasing

done
 Test injector pump
B9: Overhaul injector  Select suitable tools  Correct use of tools
 Provide workplace cleanliness and  Safety precautions adhered to

orderliness
 Clean workplace free of dust
 Remove injector nozzle body,
injector nozzle, injector spring,  Proper sitting of needle valve
disc and needle valve noted
 Injector spring tension checked

against specifications
 Spray pattern, breaking
 Fit needle valve into nozzle pressure, dribbling and leak off
tests done to specifications
 Fit disc, injector spring, adjuster
and injector nozzle body
 Test and adjust injector
B10: Fit engine  Select suitable tools  Correct use and handling of tools
and equipment
 Clean working area
 Lifting equipment fitted to
 Fit lifting equipment correct positions when fitting
 Mount all accessories to engine engine
 Fit engine mountings  All bolts tightened to specified

torque
166
 Lower engine onto mountings  Engine mountings replaced
 Fit radiator, hoses, alternator and  recommended oils and coolants

starter motor, electrical used
connections, hydraulic and
transmission pipes
 Fill radiator with coolant
 Fill oil and Check oil levels
 Connect battery
 Bleed fuel system
 Switch on master switch
 Start and run engine
 Fit covers
B11: Overhaul oil  Select appropriate tools and  List of appropriate tools and
pump equipment equipment
 Strip oil pump  Clean stripped oil pump parts
 Clean parts  Clean assembled oil pump
 Check oil pump housing for 

damages
 Check gears
 Check relief valve
167
(Plunger/Spring)
 Check bearings and shaft
 Reassemble oil pump
 Verify relevant clearance
 Check gear end float

Micrometer Trays
168

Proper use of tools
First aid
Engine to be tightly secured before lifting

169
INNOVATION SCIENCE AND TECHNOLOGY

DEVELOPMENT
DUTY C: HYDRAULIC SYSTEM
SKILLS
C1: Overhaul fixed  Select suitable tools  Correct tool and equipment  hydraulic systems o Communication
displacement handling/use applications
hydraulic pump  Observe safety precautions o Drawing
 Work area free of dirt and dust  Ratings
 Clean workplace o Reading and writing
 Safety precautions adherence  Operation of hydraulic
 Mark mating surfaces systems and o Computers
 Bushes measured for wear
 Remove bolts clamping front and specifications o Estimations
back plates to housing  Measurement and
 Clearance between housing and o Measurements
 Remove thrust plates adjustment
gear measured against o Organizing
 Remove seals, bushes/ bearings manufacturer’s specification  Removal and
installation of hydraulic o Planning
and gears from housing  Clearance between driving and
components
driven gear measured against o Analytical
 Clean, dry and inspect
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components manufacturer’s specification o Numeracy
 Fit seals  Hydraulic pump bushes to shaft o driving

clearances measured against
 Replace defective components specifications
 Fit bushes/ bearings
 Fit gears to back plate
 Fit thrust plate
 Fit gear housing and other

thrust plate
 Fit front plate
 Test hydraulic pump
C2: Overhaul  Select suitable tools  Correct tool and equipment

variable handling/use
displacement  Observe safety precautions
hydraulic pump  Work area free of dirt and dust
 Clean workplace
 Safety precautions adherence
 Block all ports and clean motor
 Piston cartridge assembly
 Mark mating surfaces clearances measured against
 Remove cap screws specifications
 Separate housings
 Remove seals, bearings from
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housings
 Remove piston cartridge assembly

from housing and shaft
 Remove swash plate from housing
 Clean, dry and inspect components
 Fit bearings and seals into housing
 Fit swash plate into housing
 Fit piston cartridge assembly onto

shaft then into housing
 Fit back housings
 Test hydraulic pump

hydraulic motor handling/use
 Observe safety precautions
 Work area free of dirt and dust
 Block all ports and clean motor
 Clean workplace
 Vane /rotor clearance measured
 Mark mating surfaces
 Rotor /housing clearance checked
 Remove cap screws
 Vane spring tension measured
 Remove/separate front and back
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covers from housing
 Remove shaft and rotor assembly

from housing
 Remove bearings and seals from

housings
 Fit bearings and seals into housing
 Fit shaft and rotor assembly into

housing
 Fit front and back covers to

housing
 Test hydraulic motor

hydraulic cylinder handling/use
 Clean workplace
 Use of correct plugs/caps on
 Remove gland securing mechanism ports
 Withdraw rod and piston assembly  Lateral/longitudinal wear on
from barrel barrel, piston, and rod noted
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 Remove piston assembly from  Positioning of seals noted

cylinder rod
 Piston and barrel clearance
 Remove gland nut from cylinder measured against manual
rod specifications
 Remove seals from piston, eyes  Bolts and nuts tightened to

and gland nut specifications
 Fit seals onto gland nut, eyes and

piston assembly
 Fit gland nut and piston onto

cylinder rod
 Fit piston and rod assembly into

barrel
 Fit gland securing mechanism
 Test hydraulic cylinder

hydraulic control handling/use
valve  Observe safety precautions
 Clean workplace
 Spool inspected for wear
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 Remove end caps  Valve block bore diameter

measured
 Remove spring retaining clips
 Pressure relief valve seat and
 Withdraw spool from valve block spring checked
 Remove seals from block  Pressure setting procedure
 Remove pressure relieve valve followed as per specifications
 Fit seals spool into valve block
 Fit springs, circlips, end caps and

pressure relief valve
 Test control valve
C6: Overhaul  Select appropriate tools and  List of appropriate tools and
signaling systems equipment equipment
 Connect gauge from main signal  Connected gauge

distribution
 Running machine
 Start machine
 Table of Pressure readings
 Activate implement

 Check pilot pressure and note
reading
 Run machine to operating
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temperature
 Record pressure
 Analyse pressure readings
C7: Inspect  Select appropriate tools and  List of appropriate tools and
electronic control equipment equipment
system
 Plug in diagnostic machine  Plugged diagnostic machine
 Run the engine  Running engine
 Note displayed fault codes  Repaired electronic control

system
 Interpret /Analyse fault codes
 Repair detected faults
C8: Inspect Swing  Select appropriate tools and  List of appropriate tools and
Motor equipment equipment
 Connect gauge  Connected gauge
 Activate rotation  Pressure readings presented
 Record pressure for both

directions
 Analyse recorded pressure
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C9: Inspect reservoir  Select appropriate tools and  List of appropriate tools and
equipment equipment
 Drain all the Oil  Empty oil reservoir
 Check drain valves where  Removed valves, hydraulic filter

necessary
 Cleaned reservoir
 Remove hydraulic filter
 Oil samples
 Remove sieve / primary filter and
clean  Running recharged machine
 Inspect reservoir condition
 Inspect reservoir for debris
 Clean and replace drain plug seal
 Send oil sample for analysis
 Assess inspection glass condition
 Recharge the oil
 Run machine and check oil level

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Micrometer Trays

Proper use of tools
First aid
Hydraulic components must be assembled in a dust free area
Components must be handled with care to avoid damage
Avoid skin contact with oils under pressure

178

DEVELOPMENT
DUTY D: UNDER-CARRIAGE SYSTEM
D1: Remove and  Select suitable tools  Correct tool and equipment  Identification of o Communication
install tracks handling/use components
 Observe safety precautions o Drawing
 Work area free of dirt and  Function of each and
 Clear workplace dust every component o Reading and writing
 Identify position of master link/master  o Computers

 Safety precautions adherence Operation of tracks
pin and track frames
 Identification of master o Estimations
 Move master link/pin to accessible  Different types of
link/pin o Measurements
position suspensions and
 Identification of tension o Driving
 De-adjust /release track tension operation
release valve
 Remove master link bolts/press out  Knowledge of the o Numeracy
 Track tension released construction and
master pin effectively operation of Track
 Move machine to and fro to layout  Safety stands used to secure Type Tractors,
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tracks machine Wheeled loaders,

Scrappers, Graders
 Raise machine and pull out tracks  Tracks to face correct way and Dump trucks
 Clean, dry and inspect tracks  Tracks tensioned to
 Construction and
manufacturer’s specifications operation of an
 Replace/repair defective components
undercarriage
 Layout / position tracks under machine
with sprocket side raised on block or  Construction and
roller operation of Track-
- type tractor final
 Lower the machine onto tracks drive and types of
sprockets.
 Connect one track link into sprocket
tooth  layout, construction
and operation of
 Use machine drive to pick up and move
hydraulic system
track into position
 Types of steering and
 Fit master link /pin into place
operation
 Grease track adjuster to tension tracks
 Types of control
to manufacturer’s specifications
valves, operation and
 Test track operation application
D2: Remove and  Select suitable tools  Correct tool and equipment
install track frame handling/use
 Work area free of dirt and
 Clean workplace dust
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 Remove tracks  Safety precautions adherence
 Put lifting equipment in place to

suspend track frame
 Remove track frame from machine
 Remove track idler from track frame
 Remove carrier rollers
 Remove load rollers
 Remove track adjuster
 Visually check for wear and damage
 Remove cir-clips
 Push out shaft
 Remove bearings
 Fit bearings
 Fit shaft
 Fit cir-clips
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D3: Overhaul track  Select suitable tools  Correct tool and equipment
adjuster handling/use
 Block all ports and clean motor dust
 Clean workplace
 Remove gland securing mechanism
 Use of correct plugs/caps
 Withdraw rod and piston assembly from
 Proper positioning of lifting
barrel equipment
 Remove piston assembly from cylinder  Measurements done to
rod ascertain degree of wear
 Remove gland nut from cylinder rod  Sprocket segments and
 Remove seals from piston, eyes and splines checked for wear
gland nut  All seals replaced
 Fit seals onto gland nut, eyes and piston

assembly
 Fit gland nut and piston onto cylinder

rod
 Fit piston and rod assembly into barrel
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 Fit duo cover seals on sprocket
 Press socket onto dead shaft
 Fit track adjuster on track frame
 Fit load rollers
 Fit carrier rollers
 Fit track idler
 Install track frame onto machine
 Install tracks onto machine
D4: Overhaul / Inspect  Select suitable tools and equipment  Correct tool and equipment
hydraulic cylinder and handling/use
Idler Wheel  Observe safety precautions
 Block all ports and clean cylinder  Safety precautions adherence
 Remove gland securing mechanism  Use of correct plugs/caps on
 Withdraw rod and piston assembly from ports
barrel  Lateral/longitudinal wear on
 Remove piston assembly from cylinder barrel, piston, and rod noted
rod  Positioning of seals noted
 Remove gland nut from cylinder rod  Piston and barrel clearance
 Remove seals from piston, eyes and measured against manual
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gland nut specifications
 Clean and inspect components  Bolts and nuts tightened to

specifications
 Fit seals onto gland nut, eyes and piston

assembly
 Fit gland nut and piston onto cylinder

rod
 Fit piston and rod assembly into barrel
 Inspect coil spring
 Remove and check the idler bearings

and shaft
 Measure guide thickness/land
D5: Overhaul  Select suitable tools  Correct tool and equipment

hydraulic control handling/use
 Remove end caps  Spool inspected for wear
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 Remove spring retaining clips  Valve block bore diameter

measured
 Withdraw spool from valve block
 Pressure relief valve seat and
 Remove seals from block spring checked
 Remove pressure relieve valve  Pressure setting procedure
 Clean and inspect components followed as per specifications
 Fit seals on valve block
 Fit spool into valve block
 Fit springs and circlips
 Fit end caps
 Fit pressure relief valve
D6: Overhaul steering  Select suitable tools  Correct tool and equipment
control valve handling/use
 Remove end caps  Spool inspected for wear
 Remove spring retaining clips  Valve block bore diameter
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 Withdraw spool from valve block measured
 Remove seals from block  Pressure relief valve seat and

spring checked
 Remove pressure relieve valve
 Pressure setting procedure
followed as per specifications
 Fit seals on valve block
 Fit spool into valve block
 Fit springs and circlips
 Fit end caps
 Fit pressure relief valve
D7: Inspect rollers  Select appropriate tools and equipment  List of appropriate tools and
and hangers equipment
 Jack the machine
 Jacked machine
 Run the machine
 Running machine
 Observe running machine for excessive
play, leakage and noise  Table of thickness of rollers,
and hangers
 Measure guide thickness/land
 Repaired machine
 Replace/ repair faulty roller/hangers
186
 Fit back all components
 Test run the machine
D8: Inspect sprokets  Select appropriate tools and equipment  List of appropriate tools and
equipment
 Measure sprocket teeth
 Table of sprocket teeth
 Replace worn out sprocket and belts measurements
 Test run the replaced sprocket  Replaced sprocket

Micrometer Trays
187

Proper use of tools
First aid
Recommended lifting equipment to be used

188

DEVELOPMENT
DUTY E: OVERHAUL BRAKING SYSTEMS
E1: Replace brake  Select tools and equipment  Suitable tools and equipment  Material science
booster selected o Communication
 Choke wheels  Types of braking systems,
 Fenders covered operation; service and o Drawing
 Disconnect battery repair
 Battery earth terminal o Reading and writing
 Detach master cylinder disconnected  Hydraulics
o Computers
 Disconnect vacuum pipe and  Push-rod adjusted to  Types of brake fluids and
o Estimations
pedal connections specifications oils -Use knowledge of
Hydraulic and -Mechanical o Measurements
 Remove mounting bolts  Work done chronologically
hand and foot brakes
o Organizing
 Mount new booster  Functions of the braking
time systems: o Planning
 Connect pedal connections
 Work done within stipulated  Mechanical. o Analytical
and vacuum pipe
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 Mount master cylinder time  Hydraulic. o Numeracy
 Connect battery  Bolts tightened to  Pneumatic.

 Start engine  operation of master
using torque
cylinders:
 Test booster operation  Wrench
 hand-brake mechanism,
brake faults:
E2: Overhaul brake  Select appropriate tools and  Battery negative terminal
 materials used as brake
master cylinder equipment disconnected
friction -material and the
 Choke wheels  Vehicle fenders covered reasons for their selection.
 Work-bench is cleaned and free  the principle operation of

 Cover vehicle fenders
of dust an air braking system.
 Disconnect battery and
 Correct use of tools done  components of a basic air
electrical connections on
braking system.
master cylinder  Master cylinder dismantled
according to manufacturer’s  braking system
 Disconnect pipes specifications
 components:
 Remove master cylinder  Visual inspection carried to
 Hand control valve.
check for scoring and wear in
 Empty brake fluid
bore  operation and layout of:
 Dismantle master cylinder  Defective parts are identified  Spring brake system.
 Inspect components  Correct replacement parts fitted  service procedure for air
 Replace defective braking systems.
 Master cylinder assembled
components according to manufacturer’s  The construction and
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 Reassemble master cylinder specifications operation of engine brakes.
 Bench test master cylinder  Safety precautions to be  Operation of the Exhaust

observed when disconnecting Braking System.
 Fit master cylinder, pipes, electrical connections
and electrical connections
 Brake fluid handling precautions
 Fill up master cylinder observed
 Bleed system  Appropriate type of fluid is used
 Connect battery  Pedal travel and clearance

measured
 Remove fender covers and
 Hydraulic system to be rid of air
wheel chokes
after bleeding
 Road test vehicle
 -Water used to clean brake
components
E3: Replace Anti-lock  Select appropriate tools and  Suitable tools and equipment
Braking system (ABS) equipment selected
 Choke wheels and cover  Fenders covered

vehicle fenders  Battery earth terminal
disconnected
 Disconnect battery, electrical
connections and fluid pipes  Safety precautions to be
observed when
 Remove mounting bolts and disconnecting/connecting
withdraw ABS unit electrical connections
191
 Fit fluid pipes  Correct ABS unit fitted
 Fill reservoir  Brake fluid handling precautions

observed
 Connect electrical
connections  Reservoir filled with correct type
of brake fluid
 Connect battery
 ABS unit tested
 Start vehicle
 Test ABS operation
 Remove fender covers and

wheel chokes
E4: Replace brake  Select tools and equipment  Suitable tools and equipment
discs /pads selected
 Loosen wheel nuts
 Fenders covered
 Jack vehicle
 Fit stands disconnected
 Remove wheels and  Safety precautions to be

disconnect electrical observed when
connections disconnecting/connecting
electrical connections
 Remove brake caliper,
 Safety precautions observed on
caliper bracket and
lifting vehicle
192
 wheel hub where integral  Dismantling of caliper, hub and

disc done according to
 Remove disc manufacturer’s specifications.
 Fit new disc  Wheel bearings inspected to

check for wear and scoring
 Clean and inspect wheel
bearings  Bearing grease used
 Grease wheel bearings  Bearings pre-loaded to

 Fit bearings, hub
 Pre-load bearings manufacturer’s specifications
using a torque wrench
 Fit caliper bracket, new
brake pads, brake caliper and  Correct parts fitted
electrical connections  New discs fitted
 Check for operation  Manufacturer’s assembling
procedure followed
 Fit wheels and torque
 Wheels tightened to
 Jack vehicle and remove
stands
using a torque wrench
E5: Overhaul brake  Select tools and equipment  Suitable tools and equipment
caliper selected
 Loosen wheel nuts
 Fenders covered
193
 Jack vehicle  Safety precautions to be

observed when
 Place vehicle on stands disconnecting/connecting
electrical connections
 Remove wheels, electrical
connections, flexible  Cleaning of components is done
hose/pipe, caliper and pads using water
 Dismantle caliper  Caliper bore is measured and

compared with manufacturer’s
 Clean components specifications
 Inspect components  Correct replacement seals are

used
 Replace defective parts
 Reassembling is done according
 Assemble caliper to manufacturer’s specification
 Fit caliper, pads, brake pipe

and electrical connections  Road regulations adhered to
during road test.
 Fill reservoir
 Bleed brakes  Hydraulic system to be rid of

air after bleeding
 Check operation
 Fit wheels
 Jack and remove stands
194
E6: Replace brake  Select tools and equipment  Correct use of tools and
shoe assembly and equipment
brake drum  Loosen wheel nuts
 No fluid spilled on body paint
 Jack vehicle
 Vehicle secured on chassis
 Place vehicle on stands stands
 Remove wheels  Correct type of brake fluid used
 Release park brake  Brakes bled until no air bubbles

appear in fluid
 Remove drum retainers,
drum, shoe return springs  All pipes connected without
stripping threads
and adjuster mechanism
 All bolts are tightened to
 Disconnect park brake cable
specified torque
 Connect park brake cable to
new shoes
 Fit shoe retainers,
adjuster mechanism and shoe

return springs
 Adjust shoes
 Fit new drum and drum

retainers
 Check operation
195
 Fit wheels
E7: Replace load  Select appropriate tools and  Correct use of tools and
sensing valve equipment equipment used
 Jack and put vehicle on  No fluid spilled on body paint

stands  Vehicle secured on chassis
stands
 Disconnect and inspect brake
fluid pipes  Correct type of brake fluid used
 Remove mounting bolts  Brakes bled until no air bubbles

appear in fluid
 Fit new load sensing valve
 All pipes connected without
 Connect brake pipes stripping threads
 Fill reservoir with brake fluid  Load sensing valve connected

according to manufacturer’s
 Bleed brakes specifications
 Check operation  All bolts are tightened to
specified torque
E8: Replace retarder  Select appropriate tools and  Use of correct tools
equipment
disconnected
196
 Choke wheels  Loosening sequence observed
 Disconnect electrical
connections
 Remove mounting brackets
 Remove retarder
 Fit new retarder and gaskets
 Fit brackets
connections
 Start vehicle
 Check retarder operation
E9: Overhaul wheel  Select appropriate tools and  -Use of correct tools and
cylinder/park brake equipment equipment used
assembly
 Loosen wheel nuts  -Battery earth terminal
disconnected first
 Jack vehicle
 -Danger warning on spring noted
 Place vehicle on stands
 -Loosening sequence observed
 Remove wheels
 -Order of friction discs and
 Release park brake separator plates noted
 -Thickness of friction discs and
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 Remove drum retainers, separator plates measured

drum, shoe return springs against specifications
and adjuster mechanism
 -Piston thickness measured
 Disconnect and inspect park  -Brakes end play checked
brake assembly and park
brake cable  -Releasing of brakes ascertained
 Disconnect brake pipes  -Drum checked for scoring
 Dismantle wheel cylinder
 Clean and inspect

components
 Replace defective
components
 Assemble wheel cylinder
 Fit wheel cylinder
 Connect park brake cable to

new shoes
 Fit shoe retainers, shoe

return springs and adjuster
mechanism
 Adjust shoes
 Fit new drum and drum
198
retainers
 Bleed brakes
 Check operation
E10: Repair  Select tools and equipment  Use of correct tools and
compressor equipment
 Disconnect water, oil and air disconnected first
pipes
 Loosening sequence observed
 Remove compressor
 Brakes end play checked
 Clean compressor
 Operation of brakes ascertained
 Disassemble compressor  Recommended cleaning solvents
 Clean components used
 Air and oil leaks checked

 Inspect components
components
 Assemble compressor
 Mount compressor
 Connect water and oil pipes
 Connect battery and start
199
engine
 Connect air pipes
 Test for operation
E11: Overhaul spring  Select tools and equipment  Use of correct tools and
applied hydraulic equipment
released brakes  Disconnect battery
(S.A.H.R)/hydraulic  Battery earth terminal
applied spring  Disconnect oil pipe disconnected first
released
 Clean component after  Danger warning on spring noted
plugging oil port
 Loosen securing bolts
 Order of friction discs and
 Take out brake assembly separator plates noted
cover  Thickness of friction discs and
separator plates measured
 Take out separator and
friction plates
 Piston thickness measured
 Take out piston
 Clean and inspect
components  Releasing of brakes ascertained
components
 Change piston seals
200
 Refit all components and fit

back cover
 Test brakes
E12: Replace brake  Select appropriate tools and  Use of correct tools and
foot valve equipment equipment
 Disconnect air pipes  Battery earth terminal

disconnected first
 Disconnect electrical
 Danger warning on spring noted
connections
 Remove mounting bolts
 Withdraw foot valve
 Releasing of brakes ascertained
connections
 Start engine
E13: Replace slack  Select appropriate tools and  Use of correct tools and
adjuster equipment equipment
 Block wheels  Battery earth terminal

disconnected first
 Start engine
 Check pressure
201
 Switch off engine  Loosening sequence observed
 Disconnect slack adjuster  Brakes end play checked

from push-rod
 Remove slack adjuster  Brakes adjusted to specifications
retaining circlip
 Withdraw the slack adjuster
 Fit slack adjuster retaining

circlip
 Connect slack adjuster to

push rod
 Adjust brakes
 Test brakes
E14: Replace brake  Select appropriate tools and  Use of correct tools
chamber equipment
 Block wheels disconnected
 Start engine  Loosening sequence followed

 Check pressure
 Switch off engine
 Cage brake chamber
202
 Disconnect slack adjuster

from push-rod
 Remove mounting bolts and

nuts
 Withdraw brake chamber
 Mount new brake chamber
 Start engine
 Check pressure
 Switch off engine
 Check operation

push rod
 Adjust brakes
203
E15: Replace brake  Select appropriate tools and  Use of correct tools and
pneumatic governor equipment equipment
 Disconnect electrical  Battery earth terminal

connections disconnected

 Disconnect air pipes
 Remove brake pneumatic
governor  Air pipes checked for leaks
 Fit new pneumatic governor
connections
 Start engine
 Check pressure
 Check operation
E16: Replace quick  Select appropriate tools and  Use of correct tools and
release valve equipment equipment
 Disconnect air pipes  Battery earth terminal

disconnected first
204
 Remove quick release valve  Brakes end play checked
 Fit new quick release valve  Releasing of brakes ascertained
 Start engine
 Check pressure
 Check operation
E17: Replace ‘S’ cam  Select tools and equipment  Use of correct tools and
shaft equipment
 Choke wheels
 Loosen wheel nuts disconnected first
 Jack vehicle and put on  Danger warning on spring noted

stands
 Remove wheels
 Remove wheel drum separator plates noted
 Remove shoe assembly  Thickness of friction discs and

separator plates measured
 Disconnect slack adjuster against specifications
from push rod
 Piston thickness measured
 Remove slack adjuster  Brakes end play checked
retaining circlip
205
 Withdraw slack adjuster  Releasing of brakes ascertained
 Withdraw ‘S’ camshaft  Defective components are

replaced
 Clean and inspect bushes
and seals
components
 Grease bushes
 Fit new ‘s’ camshaft
 Fit shoe assembly
 Fit slack adjuster and

retaining circlip

push-rod
 Fit wheel drum
 Adjust brakes
 Test operation
 Fit wheels

stands
206
 Remove wheel chokes
E18: Replace vacuum  Select appropriate tools and  Use of correct tools and
pump equipment equipment

disconnected
 Disconnect vacuum hoses
 Withdraw vacuum pump
 Fit new vacuum pump
 Connect vacuum hoses
 Connect battery and start

engine
 Check operation
E19: Adjust brakes  Select appropriate tools and  Use of correct tools and
equipment equipment
 Loosen wheel nuts  Battery earth terminal

disconnected
207
 Jack vehicle and put on  Adjusting sequence observed

stands
 Release handbrake
 Remove wheels
 Remove drum retaining

screws and drums
components
 Fit drums and drum retainers
 Fit wheels

chassis stands
E20: Bleed brakes  Select tools and equipment  Use of correct tools and
equipment
 Choke wheels
 Bleeding sequence observed
 Start engine
208
 Fill reservoir separator plates noted
 Bleed master cylinder  Brakes end play checked
 Fit transparent hose to  Releasing of brakes ascertained

bleeding nipple of furthest  Brakes bled until bubble free
wheel from master cylinder
 Immerse one end of hose

into a half filled transparent
container.
 Depress pedal a few times

and hold in depressed
position
 Loosen bleeding nipple,

allow brake fluid to drain and
observe air bubbles.
 Re-tighten bleeding screw

and repeat process until no
air bubbles are observed
 Check and maintain fluid

level
 Repeat process on other

wheels ending with wheel
nearest master cylinder
209
 Remove wheel chokes.
E21: Overhaul  Select appropriate tools and  List of appropriate tools and
hydraulic oil braking equipment equipment
system
 Connect gauge to the OBS  Running machine
regulator  Record of pressure
 Start machine  Jacked machine
 Record pressures  Drained axle oil
 Engage the brakes  Replaced replaceable
 Take note pressures to  Functional braking system

specifications
 Jack machine
 Engage in gear
 Depress brakes
 Analyse pressures and rectify

where necessary
 Take note wheels should

stop
 Observe any noise
210
 Drain axle oil
 Remove axle
 Strip trumpet housings
 Check friction discs and

plates
 Check hydraulic piston and

seal
 Clean and replace all faulty

or worn out components
 Fit back all components
 Charge oil

Micrometer Trays
211
Stocks and dies, hacksaws, chisels Overhead crane and lifts

Injector tester Parts catalogue
Standard tool box Hydraulic press/ puller
Dial indicator gauge Fire extinguisher
Brake adjusters circlip pliers
Steam cleaner

Proper use of tools
First aid
Avoid splashing brake fluid on paint or body of machine

212

DEVELOPMENT
DUTY F: PLANNED MAINTENANCE
F 1. Perform daily  Select suitable tools  Suitable tools and equipment  Different types of coolants o Communication
checks (Routine) selected
 Disconnect battery/switch off  Battery care and o Drawing
master key  Battery earth terminal maintenance
disconnected first o Reading and writing
 Choke wheels  Material science
 Battery checked for leaks o Computers
 Use, care and storage of
 Tag and lock out o Estimations
 Vee belts checked for cracks tools and equipment
 Check oil and coolant levels. o Measurements
 Recommended grease used  Different types of oils,
 Check batteries properties and use o Drawing
 Tyre pressures checked and
 Check air cleaner indicator inflated to specifications  Basic auto electrics o Organizing
 types of tyres and repair o
 Check wheels or tracks Planning
213
 Check for leaks techniques o Analytical
 Check V-belts  Types of engines and o Numeracy

operation
 Check all electrical and hooter
 types of lubricants and
 Perform walk around inspection application
 Grease machine
F2: Perform 250-  Select suitable tools  Suitable tools and equipment
hour service selected
(Minor)  Disconnect battery/switch off
master key  Battery earth terminal
disconnected
 Choke wheels
 Tag and lock out
 Check coolant levels time
 Change oil and oil filter  Bolts tightened to

 Check batteries
 Recommended oils and
 Check air cleaner indicator coolants used
 Blow air cleaner element
 Check wheels or tracks
 Check for leaks
214
 Check V-belts
 Check all electrical circuits and

hooter
 Perform walk around inspection
 Grease machine
 Check power train
F3: Perform 500-  Select tools and equipment  Suitable tools and equipment
hour service selected
 Disconnect battery/switch off
master key  Fenders covered

disconnected first
 Check coolant levels
 Change coolant filter
 Change oil and oil filter time
 Change fuel filter
 Change transmission oil filter using torque
 Check batteries  Wrench
 Check air cleaner indicator  Recommended oils and

coolants used
 Change air cleaner element
215
 Check for leaks
 Check V-belts

hooter
 Grease machine
 Adjust valve clearance
F4: Perform 1 000-  Select suitable tools  Recommended coolant used

hour service
 Disconnect battery/switch off  Recommended oils and filters
master key used
 Choke wheels  Coolant and oils filled to

specified levels
 Change coolant, coolant filter and
filter  Suitable tools and equipment
 Change oil and oil filter selected
 Change fuel filter  Fenders covered
 Change transmission oil and oil  Battery earth terminal
216
filter disconnected first
 Check batteries  Work done chronologically
 Check air cleaner indicator  Work done within stipulated

 Change air cleaner element time
 Check wheels or tracks  Bolts tightened to
 Check for leaks manufacturer’s specifications

using torque Wrench
 Change V-belts
 Clearance adjusted
hooter  Functional steering system
 Drive oil changed
 Grease machine
 Change hydraulic oil and oil filter
 Check and adjust drawbar trunion

play
 Grease and pre-load wheel

bearings
217
 Check brakes
 Check track tension
 Check steering clutches
 Change final drive oil
F5: Perform 5000-  Select suitable tools  Suitable tools and equipment
hour service
(Major)  Disconnect battery/switch off  Disconnected battery
master key
 Choked wheels
 Choke wheels  Changed changeable
 Change coolant, coolant filter and  Electrical connections checked
filter
 Physical inspection conducted
 Change oil and oil filter
 Greased machine
 Change fuel filter
 Serviced machine
 Change transmission oil and oil
filter
 Check batteries
 Check air cleaner indicator
 Change air cleaner element
218
 Check for leaks
 Change V-belts

hooter
 Grease machine
 Change hydraulic oil and oil filter
 Check and adjust drawbar trunion

play
 Grease and pre-load wheel

bearings
 Check brakes
 Check track tension
 Check steering clutches
 Check all oil pressures (Main

Hydraulic oil, Pilot Oil, engine oil,
Steering oil, swing motor oil,
Transmission oil and Drive motor
219
oil)
 Check engine blow by- breathing
 Change final drive oil

Micrometer Trays

Proper use of tools
First aid
220

Sump or differential plug tightened and oil filled

221

DEVELOPMENT
DUTY G: REPAIR GROUND ENGAGING TOOLS
SKILLS
G1: Repair ripper  Select suitable tools  Correct tool and equipment  Hydraulics o Communication
handling and use
 Clear work area  Material science o Drawing
 Disconnect battery/switch off disconnected first  Basic electrics o Reading and writing
master key  Care, use and storage of o Computers
 Safety precautions observed
tools and equipment
 Choke wheels o Estimations
 Recommended wheel chokes
 Tag and lock out used o Measuring
 Change tips and pins  New tips and pins fitted o Organizing
following manufacturer’s
 Check frame bushes, pins, seals manual o Planning
and lubricate if worn replace
o Numeracy
222
G2: Repair  Select suitable tools  Correct tool and equipment

dozer/grader blades handling and use
disconnected first
 Choke wheels
 Take off blade cutting edge used
 Turn cutting face once  New bolts used
 Replace bolts  Tightening of bolts done

 Check frame bushes, pins, seals
G3: Repair bucket  Select suitable tools  Correct tool and equipment
handling and use
disconnected first
 Choke wheels
 Change bucket bushes and pins used
 Remove seals  New bolts used
 Grease nipples  Tightening of bolts done

223
 Remove bucket tips and wear

plates
 Line bore
 Replace bolts
 Check frame bushes, pins, seals


Torque wrench Allen keys
Scrappers, files, centre punches Stocks and dies, hacksaws, chisels
Overhead crane and lifts Parts catalogue
Standard tool box Hydraulic press/ puller
Dial indicator gauge Repair manual
Lifting equipment

Proper use of tools
First aid
224

225

DEVELOPMENT
DUTY H: OVERHAUL STEERING SYSTEM
H1: Overhaul  Select suitable tools  Correct use of tools and  Material science o Communication
steering clutch equipment
 Disconnect battery  Hydraulics o Drawing
 Choke wheels disconnected first  Basic electrics o Reading and writing
 Clean machine  Proper chokes used  Knowledge of the o Computers

layout, construction
 Use of recommended cleaning o Estimations
 Remove all impediments and operation of
solvents steering system. o Measurements
 Disconnect all linkages
 Friction plates and separator  Types of steering o Organizing
 Remove cover plate plates inspected systems.
o Planning
 Remove steering clutch assembly  Due care taken on removing  Wheel alignment
steering brake band and adjustment o Analytical
 Clean steering clutch assembly procedure.
 Measurements done on o Numeracy
226
 Inspect components separator plates and friction  Types of steering

discs compared against boxes
 Re-assembling specifications
 Hydraulic-operation
 Replace defective components of a basic
hydraulically
 Assemble steering clutch assisted steering
assembly
 Fit steering clutch assembly on

machine
 Fit cover plates
 Fit all impediments
 Test and adjust steering clutch

system
H2: Repair steering  Select suitable tools  Suitable tools and

cylinder equipment selected
 Clean workplace
 Work done within
 Choke wheels stipulated time
 Block all ports and clean cylinder  Worn components

replaced
 Remove gland securing mechanism
 Withdraw rod and piston assembly manufacturer’s
from barrel specifications using torque
227
 Remove piston assembly from wrench

cylinder rod
 Remove gland nut from cylinder

rod, seals from piston, eyes and
gland nut
 Fit seals onto gland nut, eyes and

piston assembly
 Fit gland nut and piston onto

cylinder rod

barrel
H3: Overhaul  Select suitable tools  Correct tool and equipment

steering control handling/use
 Clean workplace
 Spool inspected for wear
 Remove end caps and spring
 Valve block bore diameter
228
retaining clips measured
 Withdraw spool from valve block  Pressure relief valve seat and
spring checked
 Remove seals from block
 Pressure setting procedure
 Remove pressure relieve valve followed as per specifications
 Fit seals and spool on valve block
 Fit springs, end caps, circlips, and

pressure relief valve
H4: Overhaul hand  Select suitable tools  Suitable tools and

metering unit equipment selected
 Clean workplace
 Work done within
 Disconnect battery stipulated time
 Disconnect hand metering unit  Worn components

hydraulic lines replaced
 Mark and plug open lines and  Bolts tightened to

ports manufacturer’s
specifications using torque
229
 Remove hand metering unit wrench

assembly
 marking of lines observed
 Clean hand metering unit
assembly
 Remove cap screws
 Remove/separate front and back

covers from housing
 Remove shaft, bearings, seals and

rotor assembly from housing
 Fit bearings, shaft, rotor and seals

into housing
 Fit front and back covers to housing

barrel
 Install unit
 Connect all lines
 Connect battery
 Test unit
230

Allen Trays
Hydraulic press/ puller Fire extinguisher
Steam cleaner

Proper use of tools
First aid
Dew care to be taken to avoid damaging cylinder rod and seals

231

DEVELOPMENT
DUTY I: OVERHAUL SUSPENSION
 Choke wheels and put fender covers  Safety procedures are adhered  Knowledge of oil properties o Communication
I 1: Replace to
suspension bushes  Jack and put vehicle on stands  Engine performance o Drawing
 Suitable tools and equipment
 Remove wheels are selected  Basic electrics o Reading and writing
 Disconnect hub assembly from upper  Bolts tightened to  Workshop health and safety o Computers
and lower ball joints and secure manufactures specifications  Component identification o Estimations
 Remove upper and lower control arm  Bushes fitted according to  Drawings and sketch o Measurements
 Clean and inspect components manufacturers specifications or readings
manual o Driving
 Remove bushes from control arms  Storage and care of
 Defective components are components o Organizing
 Fit new bushes on control arms and identified
grease  Lubrication system service o Planning
 Geometrical angles adjusted to and -maintenance
 Fit upper and lower control arms and o Analytical
232
connect ball joints manufacturers specifications procedures o Numeracy
 Fit wheels and remove stands  Specified grease used  Operation of hydraulic
systems, types, application
 Align wheels  Steering wheel centralized
 Different types of
suspensions
 Properties of metals
 Select appropriate tools  Safety procedures are

I 2: Replace leaf adhered to
spring  Choke wheels
 Suitable tools and
 Remove park brake cable from spring equipment are selected
 Loosen ‘u’ bolts  Bolts tightened to
 Jack vehicle and put on stands manufactures specifications
 Remove ’u’ bolts and shackle hanger
 Remove spring
 Fit new spring, ’u’ bolts’, shackle

hanger
 Connect park brake cable
 Jack vehicle and remove stands
 Select appropriate tools  Safety procedures are adhered

I 3: Replace coil
233
spring  Choke wheels to
 Cover fenders  Suitable tools and equipment

are selected
 Jack front of vehicle and support on
safety stands  Bolts tightened to
manufactures specifications
 Remove wheels
 Coil sprig aligned on pads
 Disconnect shock absorber from
knuckle  Coil spring height measured
 Remove brake fluid pipe mounting

bracket from shock strut
 Remove shock pad and withdraw

shock absorber assembly
 Clamp coil spring
 Remove shock pad retaining nut
 Remove coil spring and inspect
 Clamp new spring and fit shock

absorber and pad retaining nut
 Unclamp spring
 Fit shock pad and connect shock

absorber on knuckle
 Secure brake fluid pipe to shock

absorber
234
 Fit wheels
 Test vehicle
 Select tools and equipment  Safety procedures are adhered

I 4: Replace to
suspension air bag  Choke wheels
 Jack vehicle and support on safety
are selected
stands
 Remove air pipes manufactures specifications
 Remove air bag mounting nuts and  Airbag fitted according to
withdraw air bag manual
 Fit new airbag and air pipes  System air pressure checked to
 Jack vehicle and remove stands manufacturers specifications
 Start vehicle and check pressure  Level height sensor operation

checked
235

I 5: Replace shock adhered to
absorber  Choke wheels
 Remove upper and lower locknuts,
equipment are selected
retainers and bushes
 Inspect components manufactures specifications
 Fit new shock absorber  Shock absorber primed
 Fit upper and lower, retainer’s before fitting
bushes and locknuts  Match marks are observed
 Test vehicle

I 6: Maintain axle to
 Choke wheels
 Loosen ‘u’ bolts are selected
 Jack vehicle and put on stands  Bolts tightened to
 Remove wheels drums, brake cables manufactures specifications
 Support axle beam, brake pipes and  Brakes adjusted to

remove shock absorbers manufacturers specifications
 Remove ‘u’ bolts  Braking efficiency tested
 Lower axle  Park brake adjusted according

to manufacturers specifications
 Remove propeller shaft
236
 Fit new axle
 Support axle beam
 Fit ‘u’ bolts, shock absorbers, brake

pipes, drums and wheels
 Fit propeller shaft
 Start engine, bleed and adjust brakes
 Rest brakes

I 7: Replace torsion to
bar/ control  Choke wheels
arm/stabilizer bar  Suitable tools and equipment
 Cover fenders are selected
 Jack front of vehicle and put on
 Appropriate wheel chokes used
stands
 Remove torsion bar anchor bolt, manufactures specifications
anchor swivel and torque plate
mounting bolt  Assembling of components
done according to manual
 Remove lower arm spindle, washer
and nut from lower control arm  Wheel alignment done
according to manufacturers
 Remove torsion bar specifications
 Remove stabilizer bar from control  Defective components are
237
arm identified
 Remove control arm  Geometrical angles adjusted to

manufacturers specifications
 Clean and Inspect components
 Specified grease used
 Fit new control arm and camber
plates  Steering wheel centralized
 Fit new stabilizer bar
 Connect ball joints
 Fit new torsion bar
 Align wheels
 Test vehicle

I 8: Adjust adhered to
suspension height  Choke wheels
 Inspect front and rear tyre
equipment are selected
pressure
 Measure the distance between manufactures specifications
the centre of each front wheel to
the fender beam  Suspension height adjusted
according to manufacturers
 If the distance between the left
specifications
and right wheel is not within the
manufacturers specifications  Tyre pressures inflated or
238
adjust the height by turning the checked to manufacturer

torsion bar spring anchor bolt specifications
I9: Maintain  Choke front wheels  Choked front wheels

Tandems
 Jack machine and put on stands  Machine on stand
 Drain oil from tandem  Drained oil
 Remove wheels on tandem  Removed wheels
 Open inspection covers  Opened inspection covers
 Inspect driving chains  Worn out components replaced
 Inspect sprocket  Repaired machine
 Inspect hub bearings
 Inspect tandem main bearings
 Inspect tandem main bush
 Replace worn components
 Reassemble and put back wheels and

toque
 Charge oil to level
239

Allen Trays
Hydraulic press/ puller Fire extinguisher
Steam cleaner

Proper use of tools
First aid

240

DEVELOPMENT
DUTY J: ELECTRICAL SYSTEMS MAINTENANCE
TASK STEPS PROFICIENCY INDICATORS RELATED KNOWLEDGE WORKPLACE ESSENTIAL SKILLS
J1: Diagnose faults  Connect diagnostic machine  Diagnostic machine connected o Reading
(Fully electronic  Charging circuit
Machine)  Start the machine  Record of faults o Interpretation of results
 Safety and health
 Read faults  Disconnected machine precautions o Communication
 Interpret faults in line o Drawing

 Nature of electricity
specifications
o Computers
 Resistors
 Switch off the machine and attend
to faults o Estimations
 Inductors
o Measuring
 Magnetism
J2: Repair lighting  Select suitable tools, equipment  Correct use and handling
o Organizing
systems and safety clothing of tools  Diagnostic machines
o Planning
 Fenders, seats, steering
241
 Choke wheels wheel, floors and gear o Analytical

knob covered
 Fit fender covers, seat covers, o Numeracy
floor covers, gear lever cover  Recommended wheel
and steering cover chokes used
 Acid proof overall, goggles

 Check battery
and gloves worn
 Carry out visual inspection
 Visual inspection for
 Corrosion
 Tighten all connections
 Sulphation
 Test fuses and fusible links
 Loose connections
 Test lighting components and
circuits
 Check for short
Repair Charging  Verify battery voltage  Recorded output voltage

System
 Check cable continuity  Continuity test results
recorded
 Check associated fuses
 Alternator output voltage
 Verify alternator output voltage recorded
 Diagnose alternator and  Repaired alternator

accessories
J3: Repair instruments  Select suitable tools, equipment  Correct use and handling of
242
and safety clothing tools
 Choke wheels  Fenders, seats, steering wheel,

floors and gear knob covered
 Fit fender covers, seat covers,
floor covers, gear lever cover  Recommended wheel chokes
used
and steering cover
 Acid proof overall, goggles and
 Check battery
gloves worn
 Test components  Visual inspection done
Maintain Battery  Select suitable tools, equipment  Correct tools and equipment
and safety clothing used
 Fit fender covers, seat covers,  Fenders, seats, floor, steering

floor covers, gear lever cover covered
and steering cover  Electrical wiring diagram used
(EWD)
 Choke wheels
 Repair manual used
 Connect diagnostic tester and
record radio channels  Diagnostic machine used
diagnostic trouble codes
 Noise results interpreted
 Inspect battery correctly
 Check electrolyte level in each  Fusible links and fuses checked

for continuity
cell
 Defective fusible links and
 Check battery specific gravity
243
 Check battery voltage fuses replaced
 Check battery terminals  Drive belt checked for cracks

wear and oiliness
 Charge /replace battery
 Drive belt tension checked as
 Connect battery per manufacturer’s
specification
 Charge warning light checked

as per manufacturer’s
specifications
 Charging circuit inspected with

load i.e with headlights high
beam and air conditioner on

Standard tool box Diagnostics machine
brazing wire Multi-meter
sand-paper Hydrometer
welding rods Battery load tester
Test light workshop manuals
Regulator tester Bench tester
Insulation tape Gas bottles
Soldering iron Drilling machine
Welding machine fender, seat, floor, gear lever and steering wheel covers
244
Acid proof overalls to be worn at all times

Battery must never be short circuited so as to avoid damaging alternator
Proper use of tools
First aid
Fire fighting
Waste Management Regulations
Health Management
Responsible
Hardworking
Time conscious
Clean
Planned work habit
Professional devotion
Reliable
245

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ZIMBABWE

MINISTRY OF HIGHER AND TERTIARY EDUCATION, INNOVATION,

HIGHER EDUCATION EXAMINATIONS COUNCIL

REGULATIONS AND SYLLABUS

DIESEL PLANT FITTING

Course Code: 319/21/CR/0

Implementation Date: June 2021

1. Motor Trade Association of Zimbabwe (MTAZ) 2020

2. Motor Industry Employer’s Association of Zimbabwe 2020

5. National Railways of Zimbabwe (NRZ) 2020

6. Wankie Colliery Company 2020

1.0 TITLE AND LEVEL OF AWARD

National Certificate in Diesel Plant Fitting

2. 0 AIM OF THE COURSE

3.0 COURSE LEARNING OUTCOMES

At the end of the course the student should be able to:

3.3 maintain heavy vehicles, machinery and related components

3.6 demonstrate knowledge of technical drawing

3.7 apply communication skills to enhance performance in Diesel Plant Fitting

3.8 demonstrate knowledge of information communication technology

3.9 demonstrate patriotism on national issues

3.10 engage in entrepreneurial activities

3.11 apply acquired knowledge and skills in real world of work

SUBJECT TITLE SUBJECT NOTIONAL

6.0 ENTRY REQUIREMENTS

7.0 MODE OF STUDY

Full Time : 1 684 hours plus one year OJET

8.1 ASSESSMENT SCHEME

MODE OF ASSESSMENT WEIGHTING

10.3 The pass mark shall be 50 %.

10.4 Candidates should pass all subjects

11.1 Re-write(s) should conform to current course structure.

11.4 There is no time limit for which to re-write a failed examination.

11.5 There is no aggregation for re-writes.

11.6 All re-writes should pass on performance in the examination.

11.7 If a candidate fails continuous assessment he/she repeats the subject

13.0 IRREGULAR PRACTICES

13.2 Plagiarisms in any of the assessments will result in automatic disqualification in

14.1 Lecturers’ Qualifications:

National Diploma in Diesel Plant Fitting or equivalent, a teaching qualification

14.2 Infrastructure and Equipment

14.2.1 Theory classroom to accommodate at least 12 students per given time

14.2.4 Automotive workshop equipped as follows.

14.3 Computer Laboratory equipped with

14.3.1 12 x Personal Computers

1. Asmus A. (1981) Diesel engines and fuel system Butterworths London

2. Bland S. (1980) Diesel Engines Longman London

3. Cookery A.J. (1982) Graded Exercise in Technical Drawing Longman London

4. Crouse (1981) Automotive Electrical Systems Newness Basingstoke

6. Culphin C. (1981) Automotive Technician’s Handbook McGraw-Hill New York

7. Flood C.R. (1985) Farm Machinery Granada London

11. Kett P.W. (1981) Fundamentals of Heavy Vehicle Hutchinson

15. Nummey E.J. (1982) Vehicle Technology 2 Butterworths London

16. Pituck and (1981) Vehicle Technology 2 Butterworths London

17. Schultz E.J. Fundamentals of Motor Vehicle Hutchinson New York

18. Schultz E.J. (1983) Diesel Mechanics McGraw-Hill New York

21. Whipp J. (1982) Technical Workshop Processes & Cassell London

26 Little & (1984) Automatic Transmissions Breton London

27.. Stone R. (1985) Diesel Mechanics MacMillan London